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storm9c1 · 03-30-2016, 11:40 PM

Did you try taking a metal pick and scratching up the flat surface of the broken bolt in the hole? Weld won't stick to rust, carbon or other contamination. Scratch it up good. Maybe even get a Dremel in there if you can. Then blow it out with compressed air. And try again. You have to be a pretty good welder. Or have lots of patience. Or both. It's still a crap shoot even when you do this job right. I've ended up having to pull heads and drill/tap in a few cases. Some of these broken bolts really put up a fight.

03-30-2016, 11:40 PM	#21
storm9c1 * That's interesting * Join Date: Oct 2008 Location: Pittsburgh, PA Posts: 2,772	Re: GM LS Broken Exhaust Manifold Bolt Fix (step by step with pics)" Did you try taking a metal pick and scratching up the flat surface of the broken bolt in the hole? Weld won't stick to rust, carbon or other contamination. Scratch it up good. Maybe even get a Dremel in there if you can. Then blow it out with compressed air. And try again. You have to be a pretty good welder. Or have lots of patience. Or both. It's still a crap shoot even when you do this job right. I've ended up having to pull heads and drill/tap in a few cases. Some of these broken bolts really put up a fight. __________________ Tom Chevy by day... 1969 Chevy C30 Rollback Tow Truck -- 383 stroker, 4L80E 2011 Chevy Caprice PPV 9C3 6.0L 1995 Chevy Caprice 9C1 1994 Chevy Caprice 9C1 #3 1995 Chevy Caprice Wagon #2 1995 Chevy Impala SS Mopar by night... 1969 Dodge Charger 1972 Chrysler Newport 2dr Hardtop (27K miles) Plus others...