[V8] steel bolt in aluminum - trick

[qshipq at aol.com]

 I just spent the last few weeks doing a 20vt motor build and swap, and ran into a snapped head stud (again) due to the same problem, and went for my 20 year old trick to steel into aluminum fastener routine:

Clean the top of the fastener with wire brush and alcohol
take the welder on slow feed med/ow amp, and weld a bead onto the end of the fastener.  If flush you can weld a bead on top of a bead until you can regain a gripping head for vice grips.
Remove fastener

I've done this trick a few dozen times, and never lost a fastener imbedded in aluminum.  The flash heat on the bolt separates the steel/aluminum bond in a manner of seconds.

HTH

Scott J

 

 

-----Original Message-----
From: Rich, Jack <Jack.Rich at kronos.com>
To: Kent McLean <kentmclean at comcast.net>; a8 at audifans.com <a8 at audifans.com>; v8-list <v8 at audifans.com>; str8ightface at hotmail.com <str8ightface at hotmail.com>
Sent: Sun, Jan 3, 2010 12:41 pm
Subject: [V8] Total defeat... RE: [A8] [Fwd: Re:   steel bolt in aluminum]


I've encountered bolts that were inaccessible and I needed a lift and said to 
hell with it and gave up and had it done, but never have I encountered a bolt 
that was so easily accessible that has me totally humbled and throwing in the 
towel in complete humiliated defeat.  PB Blaster, hammers, heat, air hammer -- 
that sucker will not budge.  The good news is the car seems safe to drive even 
though the bolt has no head and no nut.  I know it isn't going anywhere.

Only question is, I can imagine that a "snap on air hammer" is a special air 
hammer that snaps or clamps into place and makes short work of removing a steel 
bolt that is now a bonded part or the aluminum housing.  However,Google results 
only show Snap-on (r) brand air hammers, which cost significantly more than my 
cheapo tool.  Maybe I just need a better air hammer, but mine is able to do the 
expected job of mangling the metal of the bolt and prove is really would have 
pushed it out if the bolt had not become one with the housing.

I'm now wandering around at a loss with no car project to work on, waiting to 
call my mechanic ini the morning.  I wonder how the hell they are going to get 
it out?  I bet they have the expensive air hammer.

Jack