Hey guys...

I need some advice. I took my exhaust manifold off to weld a crack and one of the bolts holding it on broke off in the head. I tried using an easy-out to get the remaining part of the bolt out, but the easy-out broke off inside of the bolt... which is still in the head.

Any ideas? <img src="/forums/images/graemlins/confused.gif" alt="" />

Sorry to hear about your dilemma. I have done this on more than one occasion, with success more often than not. The only sugestion I can offer requires an acetylene torch and lots of heat, enough clear access to aproach with a small cold chisel and to swing a hammer even if only with light taps. Ideally there should be at least a small protrusion of the bolt sticking out. If not, a clean flush break may be attempted. I know this sounds like a tall order, but this will be the only alternative short of removing the head and taking it to a competent machine shop. If ALL of these conditions exists, begin by heating the remainder of the bolt still in the head cherry red. Then place the very corner of the small cold chisel near the outer circumference of the bolt and attempt to rotate the bolt counter-clockwise by tapping the chisel with a hammer.

HTH,
Dave