Originally Posted by offthefront (Post 2569578)

PB Blaster wont help rusted head bolts ....The heads are just rusted up and fall apart when you try to break em loose .... when you get the bolts out you will see the threads are fine ... We just did one this week and used an air die grinder with a carbide steel bit and ground the heads off ...the manifolds will come right off and then the bolts will turn out by hand ... one note ..... try to cover and catch the metal fillings ....If you can position a shop vac as you grind will help .... The Fillings will rust .....m

Originally Posted by MOBILEMERCMAN (Post 2569594)

grind at last resort.

Originally Posted by Dave_N (Post 2569998)

Well....I wouldn't say grinding is the last resort.....the last resort is a BIG HAMMER!

Originally Posted by mcollinstn (Post 2569684)

Kroil, in my opinion, is better than PB blast. Shoot wha you can with Kroil, then add head (torch or heat gun), and then put an air wrench on it on LOW and let it sit there and hammer on it. The hammering works the Kroil into the cavities, and the heat helps too. Then add a new shot of Kroil and come back the next day. Sometimes it helps to come back on the next day and if they aren't willing to come out, add more Kroil and use the air wrench set to TIGHTEN. This works the lube into the opposite side of the threads.

If that fails, then go ahead and muscle the heads of the bolts off. Once you get your manifolds off, shoot more Kroil in and keep trying.

If you get close to the block, then you can use the failsafe method of removing the remains of the bolt.

1) grind the bolt flush with the block
2) add kroil
3) find a washer with a hole just a TOUCH smaller than the bolt diameter and drop it onto the bolt
4) Tig weld the washer to the bolt, directing the heat mostly into the broken bolt.
5) weld a NUT to the washer.
6) hammer on it a few times
7) throw an air wrench on it set to medium and zap it out.

The Kroil, the HEAT from the welding, the expansion of the bolt due to the heat, the hammer impact, the shrinking from cooling off, all of that breaks the HOLD on the bolt. It should zap right out with the air wrench.

This works on ANYTHING that is broken off in cast iron.

Mc

Originally Posted by BY U BOY (Post 2570012)

I had to do that 2 summers ago. After grinding for a day someone handed me a 8 pounder and said this should work:D

Originally Posted by offthefront (Post 2570742)

you had the wrong bit ..... we had both manifolds off in less than an hour ......

Next Time I will take mobile's advice and try the smaller socket method first .... when we got the manifolds off like I said the bolts came out by hand ..... and had NO rust on the threads .....Its just that the bolt heads are "toast" from the rust .....m