Header install NIGHTMARE
Thread Starter
Drifting
Joined: Apr 2001
Posts: 1,337
Likes: 52
From: Wentzville, MO.
Header install NIGHTMARE
I was going to save some cash and install my Kooks headers myself - wrong..
yesterday a buddy came by and we jacked the motor and got the pipes in...
today I was going to put everything back together... I busted off a header bolt pretty much flush with the block on the passager side all the way forward, on the drivers side I believe I damaged the threads on the head in the bolt hole closest to the firewall... the bolt won't go in anyway but crooked and is hard to turn way to early... I decided to put everything back together and finish the foul up minus two header bolts... most likely I'm going to have major exhaust leaks at the block :sad: I can't imagine things getting fixed without pulling the heads and I proven that I'm no mechanic... the whole ordeal makes me want to :U don't know what to do - I just had to vent to my Forum friends
yesterday a buddy came by and we jacked the motor and got the pipes in...
today I was going to put everything back together... I busted off a header bolt pretty much flush with the block on the passager side all the way forward, on the drivers side I believe I damaged the threads on the head in the bolt hole closest to the firewall... the bolt won't go in anyway but crooked and is hard to turn way to early... I decided to put everything back together and finish the foul up minus two header bolts... most likely I'm going to have major exhaust leaks at the block :sad: I can't imagine things getting fixed without pulling the heads and I proven that I'm no mechanic... the whole ordeal makes me want to :U don't know what to do - I just had to vent to my Forum friends
Drifting
Joined: Nov 2003
Posts: 1,539
Likes: 3
From: South al
Re: Header install NIGHTMARE (99SilverC5Coupe)
i am sorry to hear about your mishap on installing your headers .I know how it is to break a header bolt off in the head i did this when i put on my patriot heads i had everything back on the car & was bolting up the header bolt on the pasengers side when i broke 1 off in the head I had to pull the head back off take it to a machine shop so they could pull it out then they put a helicoil back in the hole so the header bolt fit up perfectly .Yes you will have to pull the head off to fix the problem if you ever thought about a nice aftermarket head this would be the time dont forget your head gaskets i used air in a can to clean out all the coolant that was in the holes of the block
Melting Slicks
Joined: Nov 2003
Posts: 3,011
Likes: 9
From: Dublin GA
Re: Header install NIGHTMARE (99SilverC5Coupe)
Sorry to hear about the issues with your header install. Anyone that works on their cars will experience it sooner or later.
If you want to avoid pulling the head on the passenger side, find someone that knows how to use an EZ out (bolt extracter). You should be able to get that bolt out without much issue if you're carefull! I removed the bolt next to the one you've broken on a buddys car without much problem in about 10 mins. (after the header was dropped out of the way.) Just be careful NOT to let the drill slip and cut into the head. The person will need to have done this procedure before!!
The back bolt might be more of an issue. You may try running a tap into that hold to straighten the threads if their not too damaged, before actually pulling the head. A helicoil would work best.
Good luck!! If it's any help right now, you're going to LOVE those KOOKs! :D
If you want to avoid pulling the head on the passenger side, find someone that knows how to use an EZ out (bolt extracter). You should be able to get that bolt out without much issue if you're carefull! I removed the bolt next to the one you've broken on a buddys car without much problem in about 10 mins. (after the header was dropped out of the way.) Just be careful NOT to let the drill slip and cut into the head. The person will need to have done this procedure before!!
The back bolt might be more of an issue. You may try running a tap into that hold to straighten the threads if their not too damaged, before actually pulling the head. A helicoil would work best.
Good luck!! If it's any help right now, you're going to LOVE those KOOKs! :D
Team Owner
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Re: Header install NIGHTMARE (BOTTLE FED)
:nonod: :banghead: :banghead: and I was pizzed that I broke off the bolt that holds the dipstick tube when I was putting mine back together...best of luck hope it isn't too much to fix
Pro
Joined: Nov 2003
Posts: 532
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From: herminston oregon
Re: Header install NIGHTMARE (99SilverC5Coupe)
when the engines at operating temp or hotter...then loosen the bolts a little. alum swells a bunch. try taking a punch if you can get at it, if you can get a lip maybe you can move it around. if not i've have good luck welding a nut on the bolt, be carefull!
:chevy
:chevy
Le Mans Master
Joined: Apr 2002
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From: Glendale NY
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Re: Header install NIGHTMARE (99SilverC5Coupe)
Sometimes it's a good idea to tell other people what you did. Now you know that you are not the only person who has had bad luck while attempting to accomplish a project they don't normally do. I've snapped and cross threated many a bolt. One of the worst one's was when I used a bolt that was too long for the threaded hole it was going into. It bottomed out and broke. Thanks for reminding me
Safety Car
Joined: Nov 2002
Posts: 4,394
Likes: 6
From: Melbourne FL
Re: Header install NIGHTMARE (99SilverC5Coupe)
I think everyone that has ever worked on a car has snapped off a bolt. I snapped my lower front shock mount bolt just two weeks ago.
I would try an EZ out first before pulling the head. And if you are going to replace the heads if you have to pull them off. That will give you a lot more freedom with the EZ out. You won't have to worry about screwing up the threads since you will be replacing them anyway.
Best of luck getting it out.
Did you reuse the original header bolts or was it a new bolt that snapped?
What kind of torque was on it when it snapped?
I would try an EZ out first before pulling the head. And if you are going to replace the heads if you have to pull them off. That will give you a lot more freedom with the EZ out. You won't have to worry about screwing up the threads since you will be replacing them anyway.
Best of luck getting it out.
Did you reuse the original header bolts or was it a new bolt that snapped?
What kind of torque was on it when it snapped?
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Team Owner
Joined: Apr 2001
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From: S.W. Ohio. . . . . . NRA Life Member
Re: Header install NIGHTMARE (Z06ufgrad2002)
99SilverC5Coupe; I share your frustration. As someone that can't afford to pay others to do this kind of work; I too have had many sad days as a shade tree mechanic.
You are not alone.
You are not alone.
Thread Starter
Drifting
Joined: Apr 2001
Posts: 1,337
Likes: 52
From: Wentzville, MO.
Re: Header install NIGHTMARE (Z06ufgrad2002)
Did you reuse the original header bolts or was it a new bolt that snapped?
What kind of torque was on it when it snapped?
What kind of torque was on it when it snapped?
I had reused the header bolt and I torqued it off with a zillion pounds of stupidity :crazy:
a day after the incident - I have a better perspective, my mistake will be costly...and it sucks to damage my baby but it is still just a car, in many people's lives, my own included, we deal with issues that makes my damage seem trivila..and they can't be fixed with plastic money.....
however my car can be fixed with money so if you would like to make donation to the Heads & Cam Fund for the Mechanically Challanged my email is in my profile
:jester :cheers:
Le Mans Master
Joined: Oct 2002
Posts: 6,855
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From: Grovetown GA
Re: Header install NIGHTMARE (99SilverC5Coupe)
however my car can be fixed with money so if you would like to make donation to the Heads & Cam Fund for the Mechanically Challanged my email is in my profile
:jester :cheers:
:steering:
Burning Brakes
Joined: Aug 2000
Posts: 1,132
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From: Morganton, NC, USA
Re: Header install NIGHTMARE (varkwso)
I would think the problem with using an easy out to remove the broken bolt would be access for a hand drill for the hole that needs to be straight and in the center of the broken bolt. I'd try myblackc5's method first.
Also, if you pull the head, aren't the head bolts a one-time use item that will need to be replaced when the heads are put back on?
:cheers:
Also, if you pull the head, aren't the head bolts a one-time use item that will need to be replaced when the heads are put back on?
:cheers:
Safety Car
Joined: Aug 2000
Posts: 4,537
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From: St. Joseph MO
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Re: Header install NIGHTMARE (2kbluestreak)
I would think the problem with using an easy out to remove the broken bolt would be access for a hand drill for the hole that needs to be straight and in the center of the broken bolt. I'd try myblackc5's method first.
Also, if you pull the head, aren't the head bolts a one-time use item that will need to be replaced when the heads are put back on?
:cheers:
Also, if you pull the head, aren't the head bolts a one-time use item that will need to be replaced when the heads are put back on?
:cheers:
:iagree: Good luck getting it back on the road.
Yes the head bolts are one-time use items.
Melting Slicks
Joined: Nov 2003
Posts: 3,011
Likes: 9
From: Dublin GA
Re: Header install NIGHTMARE (99SilverC5Coupe)
I'm sure by now you've decided on your course of action, but I can ASSURE you, the bolt can be removed with the EZ out procedure. I personally removed an exhaust bolt approx. 3" away from where the one you broke off is located, using a 90 degree drill and EZ out, after smoothing out the bolt face with a few stokes from a file. There was plenty of room to work, and it was actually a very simple and quick procedure.
Just do what feel most comfortable with, and good luck getting it back on the road. :steering:
Just do what feel most comfortable with, and good luck getting it back on the road. :steering:
Le Mans Master
Joined: Sep 2001
Posts: 5,857
Likes: 84
From: Gainesville VA
Re: Header install NIGHTMARE (BOTTLE FED)
I'm sure by now you've decided on your course of action, but I can ASSURE you, the bolt can be removed with the EZ out procedure. I personally removed an exhaust bolt approx. 3" away from where the one you broke off is located, using a 90 degree drill and EZ out, after smoothing out the bolt face with a few stokes from a file. There was plenty of room to work, and it was actually a very simple and quick procedure.
Just do what feel most comfortable with, and good luck getting it back on the road. :steering:
Just do what feel most comfortable with, and good luck getting it back on the road. :steering:
Drifting
Joined: May 2000
Posts: 1,413
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From: Wildwood MO
Re: Header install NIGHTMARE (99SilverC5Coupe)
Luther, that really sucks man!
Give me a call tomorrow and i'll come by and see if I can help you out. I have a few tricks that might help. I definitely know how you feel, we have all been there...
Sent you a IM too.
Give me a call tomorrow and i'll come by and see if I can help you out. I have a few tricks that might help. I definitely know how you feel, we have all been there...
Sent you a IM too.
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Re: Header install NIGHTMARE (99SilverC5Coupe)
Sorry to hear about all the problems. Hope you get it fixed.
