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Welding broken exhaust bolts

  1. #26
    Angry Gumball RandyO's Avatar
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    Re: Welding broken exhaust bolts

    heat the metal around the stud to expand the hole, and then touch an ice cube to the stud to cool and shrink the stud

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    RandyO
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  2. #27
    Lifer Tekime's Avatar
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    Re: Welding broken exhaust bolts

    I'm a little nervous about melting the aluminum with Mapp... figure I'll just monitor it with my infrared gun to about 500-600f?

    I also picked up some alum today... because... I'm tempted lol

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  3. #28
    Lifer Tekime's Avatar
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    Re: Welding broken exhaust bolts

    I couldn't resist.


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  4. #29
    Lifer Tekime's Avatar
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    Re: Welding broken exhaust bolts

    Sadly the alum experiment was unsuccessful. I couldn't keep enough heat in the solution in an unheated shop where the entire motor was acting as a heatsink. When I added near-boiling water I did some some bubbling from the stud and it appeared to be having a reaction, but the water rapidly cooled to room temp and the alum just crystallized all over the stud.

    I waffled over changing the test to crank more heat but got impatient. Drilled out both bolts and helicoiled, only took a few hours and went pretty smooth.



    Since the threads run deeper than the coils I was thinking about adding a tiny bit of JB Weld to keep them from spinning.

    Still fascinated by the alum experiment and I'll revisit it someday!

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    05GSXR75005SV65090DR350

  5. #30
    Lifer Kurlon's Avatar
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    Re: Welding broken exhaust bolts

    Normally in that case you thread the inserts as deep as they will go, and snap off the tang. Then thread another insert on top of the first till it bottoms, snap off the tang, cut the excess coil flush.

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  6. #31
    Rookie Rada's Avatar
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    Re: Welding broken exhaust bolts

    Solid work. Make sure you anti=seize the piss out of the new bolts

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  7. #32
    Lifer Tekime's Avatar
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    Re: Welding broken exhaust bolts

    Quote Originally Posted by Kurlon View Post
    Normally in that case you thread the inserts as deep as they will go, and snap off the tang. Then thread another insert on top of the first till it bottoms, snap off the tang, cut the excess coil flush.
    Man I was on the fence about that. I'm using a cheap helicoil kit and the tangs almost never break off clean (or maybe I just have poor technique). I decided the chances of me ruining it completely and pulling the coil out were too high so I just flushed the insert and called it good. If it gives me an issues I will pull the inserts and try doubling them up.

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  8. #33
    ^ It's my bike and my car tls25rs's Avatar
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    Re: Welding broken exhaust bolts

    Or, if you have a deep hole that needs to coiled you buy a longer heli-coil. They come in many lengths, typically 1x, 1.5x, 2x etc. the diameter of the bolt hole you are coiling

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  9. #34
    Where is my fast? GixerJockey's Avatar
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    Re: Welding broken exhaust bolts

    ^ this guy knows about deep holes

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