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Go Back   SailNet Community > On Board > Gear & Maintenance > Advice on removing snapped s/s bolts from alu block
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Topic Review (Newest First)
10-08-2012 08:28 AM
eko_eko
Re: Advice on removing snapped s/s bolts from alu block

I've had this exact problem. I've tried most of the solutions posted here, including an oxy-mapp torch.

The thing that worked in the end: an arc welder.

There's corrosion between the bolt and the surrounding aluminum. It's frozen in place.

The current from the welder broke it free in under a second.

Take it to a shop with a welder. Ask them to pull the bolt.
10-08-2012 01:35 AM
hellosailor
Re: Advice on removing snapped s/s bolts from alu block

Mark, fastest cheapest best result might be to just find a good machine shop, let them deal with it. If the machinist has any doubts, find a better shop.

PBlaster is great stuff, it chemically attacks the corrosion. So does Kroil--but you have to mail order that.

Torches are nice but can weaken the metal. A CO2 extinguisher or small tank of CO2 from a gas shop can do the same thing by freeze-soaking the parts. Slotting the bolt with a Dremel and using an impact hammer is also good, I'd try the PBlaster and freeze cycling it 3-4 times before whacking away at it, in that sequence. And if none of that worked, THEN center punch it and carefully drill out as much as you can. In the worst case, you overdrill and use Heli-Coils. But a good machine shop can put that engine in a drill press and chew the studs out, or they can weld a crossbar onto them and then just spin them out.

I'm going to guess they'll get rid of the bolts for under $50, as opposed to screwing around all afternoon worrying about it. Hardest part of the job would be finding a good machine shop.
10-06-2012 10:37 AM
Sea Dawg
Re: Advice on removing snapped s/s bolts from alu block

Quote:
Originally Posted by RobGallagher View Post
PB Blaster is great. This might be better.

Google Deal
oh yeah, +1!
10-06-2012 05:36 AM
RobGallagher
Re: Advice on removing snapped s/s bolts from alu block

PB Blaster is great. This might be better.

Google Deal
10-06-2012 03:25 AM
sww914
Re: Advice on removing snapped s/s bolts from alu block

Heat, impact, PB Blaster.
10-06-2012 12:42 AM
flyingriki
Re: Advice on removing snapped s/s bolts from alu block

Quote:
Originally Posted by chucklesR View Post
Use a dremel and cut a groove for a flat head screw driver, soak it in PB Blaster or the lube of your choice then back them out with a hammer drill.
+1.......worked for me on almost every screw on my boom....
10-05-2012 09:23 PM
exkma367
Re: Advice on removing snapped s/s bolts from alu block

I used to work with a welder who would tig the top of the bolt building it up until you could put vice grip pliers on the buildup. The heat from the tig went a long way toward loosening up the bolts. I have seen him do it on #8's broken off in the hole. If you are going to drill, buy the correct size left hand drill bit. It will be nice to have in the tool box in any case. Turning the bolt in the correct direction while drilling may give you a pleasant surprise.
10-05-2012 08:50 PM
Sea Dawg
Re: Advice on removing snapped s/s bolts from alu block

The old adage applies, "Experience comes from equipment ruined!". Just where does all that experience/wisdom come from?
10-05-2012 07:34 PM
MarkSF
Re: Advice on removing snapped s/s bolts from alu block

The two bolts in question are surrounded by the gasket, so leaking should not be an issue. I'm willing to have a go at removing the bolts, and maybe helicoiling, but taking the block to a machine shop is probably not economic, given the price of a new block.

I'll let you know what transpires!
10-05-2012 07:31 PM
dabnis
Re: Advice on removing snapped s/s bolts from alu block

For $240 for a new block, you don't have much to lose by trying to drill and tap. I used heli-coils on motorcycle spark plug holes and was not aware of leaking but if in a water jacket you wouldn't know until you re-assembled everything. New block looks better considering your time?

Paul T
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