broken water pump bolt

[Young Ed]

Ok confession is good for the soul right? Dad and I broke off one of the bolts in the engine I got from Merle for my next project. Was getting close to having the 5spd hooked up behind it too. I tried to drill it out and of course got off center. I stopped when I noticed but I think the damage was already done. And the remnants are still stuck in the hole. What are my options here? Time to find a 25" block and go for some more power or can I still save the little 218?

[David Strieb]

Can you go to a smaller bit and refind true center? When I broke my distributer bolt off, I used a small die grinder to create a good center point for the drill, maybe a die grinder can be used to eat away at the remaining bolt? Left handed drill bits do wonders on broken bolts. If the engine is out of the car, a machine shop should be able to help. Hope you can fix it.

[RobertKB]

Finish drilling it out and retap to the next size up? I just hate it when that happens as I have been there and done that. Good luck!

[Young Ed]

I looked and it doesnt look like the water pump will allow the next size up bolt. Unless I did something odd like a stud that was 2 different sizes. I suspect the best thing might be to just haul it out to our trusted machine shop and pay the piper to fix my mess.

[Plymouthy Adams]

as the block is cast iron and the bolt is steel..you can blow the hole with the cutting torch and not do damage..(especially if this is a blind hole)...cast iron is easy enough to tap and maybe you could helicoil the hole now once the original bolt is blow out...if a blind hole..may be a bit harder to insert as you will need a bottom drill, and a bottoming helicoil tap..

http://www.helicoil.com.sg/HeliCoil-STI-Taps.htm

Edited April 27, 2010 by Tim Adams

[Young Ed]

Nope not a blind hole goes right into the water jacket. I suspect part of the issue was the bolt seemed too long and was probably sticking into the water and rusting. Because it came out most of the way and just wouldn't finish. Dad and I took turns turning the bolt in and out for a long time. It seemed like each time it was going a little further and a little further but eventually it broke.

[1just4don]

is the end flush or better? my guy takes a nut and wire welds it fast on the inside. then puts a wrench on nut and turn it out. the heat actually helps the whole process. works pretty darn close to 100 % of the time. even if its less than flush cause the weld wont stick to the cast well. Take your time and breathe twice,,,this will be okay!!!! (cause your a good welder)

[Young Ed]

The broken piece it 1/2 way down the hole. Probably 3/8s of an inch in.

[Jerry Roberts]

The broken piece it 1/2 way down the hole. Probably 3/8s of an inch in.

If you thread in a short ( 3/8th inch ) stud with a hole centered , could you now drill a center hole in the old stud using the new stud hole as a guide ? Just a stab in the dark .

[JBNeal]

Surgical strike with the blow torch, you can try to blow it out into the water jacket, where it'll make ugly b-b's that'll need to be flushed out. The cast iron can take the residual heat as long as it is allowed to cool with ambient temperatures. If thread are waller'd out too much after chasing the threads clean, try the helicoil repair.

[Flatie46]

Could you post a pic? Can you bolt the waterpump back on and use the hole in the pump as a guide and mabe get back in the center?

[greg g]

Can you cut a slot into it and screw it in through the hole and let the stub just rettle around in the WJ???

[55 Fargo]

I am with Tim Adams and 49 Dodge1ton, blow it out with a torch,then clean up threads.

Or take it in to a machine shop, where they can drill this out on center somehow, very difficult, once off center.

I went through this on an exhaust manifold stud, not fun. it was actually a bolt, so was able to tap to next size, luckily.

I know you will find the way Ed, keepin my fingers crossed for you.........Fred

[Greenbomb]

Uh oh! Sounds like trouble! I got 2 of my waterpump bolts out, but the third one (The one that holds the gen. bracket) won't move and I rounded it off. Anyone ever use one of those Sears sockets thats spose to get a death grip on rounded off bolts? I think I'm gonna try one. Anyway, let us know how you make out with yours.

[Plymouthy Adams]

death grip it is..I removed some seat bolts on a J-car once that were so rusted and rounded there was nothing a normal socket could use as a flat..they unbolted like a dream..they sure are amazing sockets...reverse easy out design...use them once and they have paid for themselves...on your bolt..if it is that bad that you are already in this rounded head condition..I would highly suggest a couple heat cycles of the bolt in question with the ole torch to kill the rust..two cylce to red should come close to doing the job..on the cool down of the second heat..place a candle agaist the base and let it suck in some wax for lube...do not use oil here while bolt is hot...

[Young Ed]

With that type of bolt I think I'd cut the head off and use a stud remover. And Tims heat suggestion!

[Greenbomb]

Good idea on the heat-I'll do that. Thanks.

[Young Ed]

Update. Bolt is still not out. Engine is going to our trusted machine shop saturday for him to take a look at. I need to determine my line in the sand on cost. This engine is a used 218 I bought from Merle. It appears to have been rebuilt once upon a time by all the odd ball fastners used on it. Thats what caused the waterpump issue. So it doesnt make sense to spend a ton of money on an engine with a sketchy past.