Broken bolt removal, time to revisit.....

[mcfarmall]

If you think aluminum and steel are unfriendly, you should witness the feud between brass and aluminum. I worked at a company that made aluminum air con tubing and heater pipe for cars. We bought a used CNC tube bender that was out of a plant that made brass heater pipe. When our customer found out that we were planning on using for aluminum tubing, they about hit the ceiling!! if even one tiny flake of brass gets mashed into the surface of an aluminum heater pipe, the galvanic corrosion will bore a hole straight through the aluminum after a few years.

 

[Oldpath05]

If you think aluminum and steel are unfriendly, you should witness the feud between brass and aluminum. I worked at a company that made aluminum air con tubing and heater pipe for cars. We bought a used CNC tube bender that was out of a plant that made brass heater pipe. When our customer found out that we were planning on using for aluminum tubing, they about hit the ceiling!! if even one tiny flake of brass gets mashed into the surface of an aluminum heater pipe, the galvanic corrosion will bore a hole straight through the aluminum after a few years.

Is that right, I thought brass worked well with every metal, seems like everyone's posting stuff on here I never heard of.

 

[Oldpath05]

I got it, only took me 5hrs to do this muffler job, your right that was fast. I tried the bolt on washer trick on this last one, wanted to try the wax trick to to prove that wouldn't work, but the wife went shopping before I got going and I didn't feel like turning the house upside down looking for it. So I welded the washer on, then a 3/8 nut on that, waited for the red glow to go down then I tried to turn it. It was a no go, peeled out a 16th below surface.

So back to the backwards drilling, 1/8 then 3/16 then the forward 13/64 bit, then tapey time, side notes>>>(be careful tightening drill chuck with drill key when air hose is plugged in, ouch) and when/while drilling hole, watch from 3 different angles so end result is a straight hole @90ｰ from motor block)<<That last hole is half a air off from perfect but the muffler bolted on, with a little might not Never Seize, I put it back together, so Yippee ki-yay and drinks all around, I'll send myself the bill next year for this muffler job.

 

[CincyFlyer]

Brass studs, with brass washers and nuts are fairly common in holding exhaust manifolds on in Japanese cars. What you might end up doing if you mess up the threads is to source some from a parts store that will fit through the new muffler, both diameter and length, and helicoil the cylinder to take them.

I've see the brass nuts, but never have I seen brass studs.

 

[flyerdan]

You know, I don't have a head out in the shop to check, but it does make sense that the studs would be steel. They would be less subject to distortion, and as long as brass nuts were used disassembly wouldn't be a problem. I never had any reason to remove the studs, so I obviously didn't pay that much attention to them.

 

[whitepine2]

KROIL seems to work MUCH better than PB Blaster.

And "GIBBS" is better than both!

 

[Oldpath05]

Gibbs Brand Lubricant (2-12oz cans) - Power Tool Lubricants - Amazon.com First Ive heard of it, does get the 5 star vote.....

 

[whitepine2]

Gibbs Brand Lubricant (2-12oz cans) - Power Tool Lubricants - Amazon.com First Ive heard of it, does get the 5 star vote.....

Try it you will like it,I used KROIL by the five gal can it was best for years until GIBBS may-be something better but I'v not found it.

 

[toy]

I always use left hand drill bits and they do work.