Well here is the problem ..... When my uncle took off the turbo he broke a header bolt in the head. There is some langth on the bolt sticking out but is completly rounded.... How do i get it out? I heated it up and tryed vice grips to loosen it up NO GO i tryed putting flat sides with a dremal and put a wrench on it but NO GO now it is back to a rounded pieace of bolt sticking out what do i do help.....here is a pic

[IMG]local://upfiles/12817/A0BEA0E7E399495C8FAAFF8038ABEE9C.jpg[/IMG]

 

that is a horrible picture i must say but you're probably going to have to get a tape and dye set and drill it out and get a new stud.

 

I guess the question is, what is holding it in? torque or rust... if it is rust i would spray a healty amount of PB Blaster on it and let it sit overnight... if it is torque you are on the right path of making it square on the sides and using an adjustable wrench to turn it out... i would still use the pb blaster though... its like wd40 but 10 times better.... i dont think the tap and die thing will work cuz you probably wont get enough torqu to loosen it unless you have an impact wrench... the other thing you coud try is a "gator grip" they have them at walmart.... make the bolt square and use it on a wratchet with a breaker bar, or impact wrench. let me know how it goes.

 

If all else fails you could proablby drill it and use a screw extractor.

 

Try the oil 1st, Aluminium core & metal bolt, usually its the aluminium that causes it to tighten (whitish oxide that forms on it) add a little rust & hey presto seized bolt. Do you guys have "Ezy outs" ? Only other suggestion, file it square & use a impact wrench.

 

get a vice grip and give it hell

 

IM gonna try the vice grip again with the heat then ill try the gator grip then ill have to tap or easy out it gonna have to get it out some how if i have to re tap the threds i will that will suck but what ever .... do i have to worie about water jackets being really close by????

 

that pic is hard to see. i had something similar happen to me when removin a rear sprocket one of the nuts got round out so the allen key would not work. i took it to a shop n the guy made a t bar like n tac welded it cooled off put it in a vice n out she came. but i also sprayed the hell out with wd 40 first . if a piece can be tacked on u might wanna try that .

 

you may have to try and notch it so you can use a a big flat head. You never know it may work.

 

You say you heated it up. Wouldn't that make the bolt expand and make it even harder to get out? What about cooling it down and then trying to remove it.