[V8] steel bolt in aluminum - trick

[Jason Wilkerson]

Great trick - I've done it too - works great.  I will add that you can weld a large nut up there too - you can weld on the inside of the nut to the top of the broken bolt.  That works great for snapped exhaust studs.  Good luck.

--- On Mon, 1/4/10, qshipq at aol.com <qshipq at aol.com> wrote:

> From: qshipq at aol.com <qshipq at aol.com>
> Subject: Re: [V8] steel bolt in aluminum - trick
> To: Jack.Rich at kronos.com, kentmclean at comcast.net, a8 at audifans.com, v8 at audifans.com, str8ightface at hotmail.com
> Date: Monday, January 4, 2010, 11:19 AM
> 
>  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
> 
> 
>  
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