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Old 07-07-2013, 01:46 PM   #4
GASoline71
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Join Date: Sep 2007
Location: Whidbey Island, Washington
Posts: 8,921
Re: GM LS Broken Exhaust Manifold Bolt Fix (step by step with pics)"

Pic #1, Break out the Lincoln 140C

Pic #2, There is a perfect spot on the block right below the head to put the welder ground on. I used a small angle grinder to take off the rust. Remember to unhook the negative terminal on your battery before starting to weld.

Pic #3, Thick washer that was a tad smaller than the hole, and a nut. I penetrated the washer perfect on the first try. However, I used 3 different nuts because due to the angle you have to weld at, it was hard to get penetration on the inside the nut. So I finally used a bit bigger nut and gave a good hot tack on the outside of the nut to the washer. Also the first 2 nuts, I didn't have the heat up enough. The bigger nut, I turned he heat up all the way, and had the wire speed on 5. In hindsight... the wire speed could have went to 6.

Pic #4, Washer held on with duct tape. No rom to hold it with a gloved hand. Be quick to blow out any burning tape. It WILL catch fire... trust me. But it's not a huge fire. Just be aware that you have to blow out the fire. I had a compressed air hose at hand with a nozzle.

Pic #5, First attempt at welding the nut. Held nut with tape too. This nut spun off when I put a socket on it.
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My 1972 GMC 1500 Super Custom (Creeping Death) "long term" build thread.

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Last edited by GASoline71; 07-07-2013 at 02:25 PM.
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