so i was putting on my new header when one of the bolts snapped off. twice. i've tried penetrating oils, screw out systems, cobalt drill bits, titanium drill bits + now i'm working on stone jewler's grinding tips.

is there something that i can do aside from taking my car to a shop? i neeed help asap!!!!

 

if some of the threaded bolt is still sticking out, theres a fun trick i end up using a lot.

thread a nut onto it. now thread another nut onto it. put your socket over both nuts. crank on it.

if its all the way in, id hit it with the cobalt bits. i had to drill out my caliper bolts with them, it took a while but it worked.

also when you finally do get it out, id recommend re-tapping. if its real bad, get a helicoil, and repait it.

 

Several things you can try.

First, weld a nut onto the exposed end of the bolt. Obviously, this only works if you have a welder. The nut gives you something to turn, and the heat generally brakes the corrosion holding it in place.

Failing that, drill it out and tap. Grind the broken end flush, then center punch. Drill out in several steps to keep the hole centered. Then tap.

 

Heat it up with a torch, then put vise grips on it. A lot of the time that works.

 

yeah. i tried all of that (except the welding a nut. i don't have access to a welder.)

ended up using a crap load of red rtv stuff around it along w using the old + a new gasket. waited a day for it to cure all the way then started it up. after it did finally start up (it was flooded. got the famous rotary smoke show :P ) the wrap on the header smelled really bad as it burnt off. i took her for a drive on the freeway. got some good power out of the new header. + it seemed to seal completely. so i guess if/when that starts to go, i'll take it to a shop + have them have a wack at it. if that doesn't work...... hello rebuild