Screwed up big time.

[Ritchie_Rich]

I know a long-time Chevy dealer mechanic who has probably extracted manifold bolts on a hundred trucks over the years (yes, broken manifold bolts are very common on the 6.0L Chevy 2500HD trucks). If it is broken flush or below the surface of the head they automatically pull the head and send it to a machine shop. The machine shop has the ability to make sure the drilled hole is 100% straight and centered and always works without messing up the threads. He said that it's not that much more work or cost, and simply much easier for them.
With that said I have extracted several manifold bolts at home using the welder method.

And the 454. I did quite a few of them back in the day.

 

[Dougstr]

How to repair head in truck. Drill out the hole big enough to install a way bigger bolt. Thread the hole so the bigger bolt will thread in snug. Cut the bolt off and grind the bolt even with the head. Then grind smooth drill and tap the new bolt to fit original manifold bolt in it. Make sure when installing the new bolt it is as close to center of where the old smaller broken bolt was. Once done trouble free repair. This does work I know from experience with over 50 yrs as a tech with allot of field repairs. You can use a aluminum bolt to thread into the hole drilled then drill the trimmed down bolt. Have to think outside of the box

 

[Hardracer]

The problem I really see on this job is he got off center....I've removed more bolts than I can count over the last 30 years on outboard engjnes.Done it every way you can think of.Over the last 3 months or so I've removed around 14 Ls manifold head bolts.......about 3 if those gave me some serious problems that took me to drastic measures(out of the ordinary easy ways)....you also have look at why the bolt broke...I understand why ours break but others can be corrosion(not our motors).my main issue is of the dis-similar metals of stainless to alum.along with the saitwater......a real bear on alot of them...dont care what you do when there so corroded and festered in,your drilling them out...no heat with and ez-out,no welding a nut on....it just ain't happening.im pretty good at it and can tell right off the bat what its gonna take to get one out..The OPs best bet now is to change out the head in his time crunch being off center like it is.
That's my views on the subject.

 

[04fxdwgi]

And the 454. I did quite a few of them back in the day.

And the 66-71 Hemi cast iron. About 95 + - pounds. I know, I had 3 of them and every one got built.

 

[Dusty]

I believe (most) Ram dealers have a special tool that mounts to the head and acts like a pilot guide for drilling.

Regards,
Dusty
2019 Ram 1500 Billet Silver Laramie Quad Cab 2WD, 5.7 Hemi, 8HP75, 3.21 axle, 33-gallon fuel tank, 18” wheels. Build Date: 3 June 2018. Now at 141806 miles.

 

[Grams]

The problem I really see on this job is he got off center....I've removed more bolts than I can count over the last 30 years on outboard engjnes.Done it every way you can think of.Over the last 3 months or so I've removed around 14 Ls manifold head bolts.......about 3 if those gave me some serious problems that took me to drastic measures(out of the ordinary easy ways)....you also have look at why the bolt broke...I understand why ours break but others can be corrosion(not our motors).my main issue is of the dis-similar metals of stainless to alum.along with the saitwater......a real bear on alot of them...dont care what you do when there so corroded and festered in,your drilling them out...no heat with and ez-out,no welding a nut on....it just ain't happening.im pretty good at it and can tell right off the bat what its gonna take to get one out..The OPs best bet now is to change out the head in his time crunch being off center like it is.
That's my views on the subject.

Awww… That’s CHEATING…unless the TAP ….and the BOLT you install to “fill” the hole… is LEFT HAND THREADS!

 

[EdGs]

If you use a left-hand drill bit, sometimes while drilling for an ez-out, it will catch enough to back the stud out.

I personally would only attempt to drill the stud if I had a drill template. I don't trust my lazy eye enough....lol.

 

[Wild one]

Awww… That’s CHEATING…unless the TAP ….and the BOLT you install to “fill” the hole… is LEFT HAND THREADS!

JB Weld works to hold a bigger bolt in place.I've done this fix, "once" and would never do it again,but i used JB Weld to hold the replacement bolt in place before drilling and tapping it

 

[Hagar1]

Ouch, but could be worse.

Please tell me you are not a gastroenterologist because if I see you at my next colonoscopy I WILL run screaming into the street.

But ...... just think, he might be able to do the entire job through the tail pipe! Now, THAT would be talent!

 

[Hagar1]

If you use a left-hand drill bit, sometimes while drilling for an ez-out, it will catch enough to back the stud out.

I personally would only attempt to drill the stud if I had a drill template. I don't trust my lazy eye enough....lol.

At my age, I have 2 lazy eyes so definitely a template is needed.

 

[Hardracer]

All these statements after my post are true....but as they say...there is more than 1 way to skin a cat....lmao
To Hagar...my eyes definitely are not what they use to be...it happens to best of us
To Grams..I value your input 100%..I've read alot of your posts and you are spot on 99%of the time......no quarrels with anything you've ever posted that I've read....again,spot on....the fact about the reverse thread is also spot on....although I have never done a reverse thread deal in this kind of scenario.......but that has never posed a problem for me throughout my time when doing a job ,you did bring up a good thought to me though....."ya that makes sense"....I value your input...well done sir!.....rick was also right when I said larger bolt(although i didn't mention what I do to lock it in place)ive used jb weld,loctite,welding,few center punches,etc...i definitely use whatever locking/sealing method to keep that bolt in place for the re-centering drill of the original size....just the way i do things to make it work for the customer.....most of the time i'm tack welding it in place and a nice file smooth finish...my s**t ain't gonna back out...that just isn't proper for me......I wouldnt want my own stuff coming loose so I'm not gonna be giving that back to a customer in a way that it could......I have an OCD problem with stuff like that and my boss allows me to be that way.....
I've enjoyed this conversation on the matter.

 

[Wild one]

All these statements after my post are true....but as they say...there is more than 1 way to skin a cat....lmao
To Hagar...my eyes definitely are not what they use to be...it happens to best of us
To Grams..I value your input 100%..I've read alot of your posts and you are spot on 99%of the time......no quarrels with anything you've ever posted that I've read....again,spot on....the fact about the reverse thread is also spot on....although I have never done a reverse thread deal in this kind of scenario.......but that has never posed a problem for me throughout my time when doing a job ,you did bring up a good thought to me though....."ya that makes sense"....I value your input...well done sir!.....rick was also right when I said larger bolt(although i didn't mention what I do to lock it in place)ive used jb weld,loctite,welding,few center punches,etc...i definitely use whatever locking/sealing method to keep that bolt in place for the re-centering drill of the original size....just the way i do things to make it work for the customer.....most of the time i'm tack welding it in place and a nice file smooth finish...my s**t ain't gonna back out...that just isn't proper for me......I wouldnt want my own stuff coming loose so I'm not gonna be giving that back to a customer in a way that it could......I have an OCD problem with stuff like that and my boss allows me to be that way.....
I've enjoyed this conversation on the matter.

I swear by JB Weld,lol. I've glued engine blocks back together using it When you're in the field you do what ya gotta do to keep things running till replacement parts show up

 

[Hagar1]

All these statements after my post are true....but as they say...there is more than 1 way to skin a cat....lmao
To Hagar...my eyes definitely are not what they use to be...it happens to best of us
To Grams..I value your input 100%..I've read alot of your posts and you are spot on 99%of the time......no quarrels with anything you've ever posted that I've read....again,spot on....the fact about the reverse thread is also spot on....although I have never done a reverse thread deal in this kind of scenario.......but that has never posed a problem for me throughout my time when doing a job ,you did bring up a good thought to me though....."ya that makes sense"....I value your input...well done sir!.....rick was also right when I said larger bolt(although i didn't mention what I do to lock it in place)ive used jb weld,loctite,welding,few center punches,etc...i definitely use whatever locking/sealing method to keep that bolt in place for the re-centering drill of the original size....just the way i do things to make it work for the customer.....most of the time i'm tack welding it in place and a nice file smooth finish...my s**t ain't gonna back out...that just isn't proper for me......I wouldnt want my own stuff coming loose so I'm not gonna be giving that back to a customer in a way that it could......I have an OCD problem with stuff like that and my boss allows me to be that way.....
I've enjoyed this conversation on the matter.

Yup! Gone are the days when I could sharpen a 1/8 drill bit free hand and it would cut. Now, well, lets just say it ain't going to work for me any more.

 

[EdGs]

Yup! Gone are the days when I could sharpen a 1/8 drill bit free hand and it would cut. Now, well, lets just say it ain't going to work for me any more.

OMG! I can't sharpen a drill bit worth a crap....lol

 

[Grams]

…
To Grams..I value your input 100%..I've read alot of your posts and you are spot on 99%of the time......no quarrels with anything you've ever posted that I've read....again,spot on....the fact about the reverse thread is also spot on....although I have never done a reverse thread deal in this kind of scenario.......but that has never posed a problem for me throughout my time when doing a job ,you did bring up a good thought to me though....."ya that makes sense"....I value your input...well done sir!.....

…

I've enjoyed this conversation on the matter.

The check is in the mail….

 

[Ken226]

OMG! I can't sharpen a drill bit worth a crap....lol

I use a drill Dr 750. There is a learning curve, and some tips and tricks not covered in the manual. And you defintely gotta read the manual a couple times.

A few dozen YouTube videos should cover most of the little hacks that give better results. Like doing split points, adding shims to position the grinding wheel better, etc.


But, since I started using it back around 2018, I use up drill bits untill they about an inch and a half long before they get tossed. Kinda like a #2 pencil, except it takes me a few years to use them up all the way.

Drill Doctor DD750X Electric Drill Bit Sharpener, 3/32-3/4" High-Speed, Portable - Steel, Masonry, Carbide, Cobalt, Tin-Coated Bits, Adjustable Angles https://a.co/d/bT79ivl

 

[Hagar1]

That is what I'm down to these days. It is frustrating at times, the mind is still pretty sharp but the things the mind plans for the day, the rest of the body says ........ you are joking, aren't you?

 

[Wild one]

I use a drill Dr 750. There is a learning curve, and some tips and tricks not covered in the manual. And you defintely gotta read the manual a couple times.

A few dozen YouTube videos should cover most of the little hacks that give better results. Like doing split points, adding shims to position the grinding wheel better, etc.


But, since I started using it back around 2018, I use up drill bits untill they about an inch and a half long before they get tossed. Kinda like a #2 pencil, except it takes me a few years to use them up all the way.

Drill Doctor DD750X Electric Drill Bit Sharpener, 3/32-3/4" High-Speed, Portable - Steel, Masonry, Carbide, Cobalt, Tin-Coated Bits, Adjustable Angles https://a.co/d/bT79ivl

I have the old version of that,lol. My Drill Doctor is probably close to 25 years old now,and has saved alot of drill bits over the years

 

[4xdad]

Hagar1 I feel you brother. I am fighting prostate cancer. The estrogen pills that I take leave me weak as a kitten. Back in the day I would bench press a transfer case in to position while my buddy would put it bolts in. Now I can only work on my truck for a couple of hours and I am done.

 

[EdGs]

Hagar1 I feel you brother. I am fighting prostate cancer. The estrogen pills that I take leave me weak as a kitten. Back in the day I would bench press a transfer case in to position while my buddy would put it bolts in. Now I can only work on my truck for a couple of hours and I am done.

@4xdad, very sorry you are going through this, sending prayers for you and your family.