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Old 05-01-2011, 08:15 PM
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help with broken intake bolt

i am doing a cam/lifter, carb/ intake swap on my ford 302 and when i was taking the old intake bolts out i broke the head off one of them..i got the old intake off but i got a broken bolt stuck in the back driver side head.. it almost broke off flush so i cant get a pair of vise grips on it..what can i do to fix this ...

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Old 05-01-2011, 08:21 PM
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Iron head? If so, torch it until its really hot. You won't be able to go red hot, but if you do it when its dark you can go until it glows slightly. Immediately stick a candle on it and let the wax melt into it. It will kinda act like flux and get sucked into the threads. Then drill and use an ez-out on a cordless impact. If that doesn't work, you're looking at drilling out the whole thing and heli-coiling, but before you spend money on that, compare the cost of a used head.
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Old 05-01-2011, 08:24 PM
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If you have a mig welder, weld a nut onto the bolt. Most times the heat from welding will loosen the bolt and it'll come out easy. I'd be wary of drilling it for an easy-out, because if you break one of those off in it, your kind of screwed.
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Old 05-01-2011, 08:45 PM
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dont have a welder and dont think i could weld a nut on it without welding to the head...wonder what a machine shop would charge to fix it...wouldnt mind finding a good flowing set of better than my stockers but i dont know much about heads so i wouldnt know what was good or not...they would have to be ready to bolt on if i lucked up and found a set
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Old 05-01-2011, 08:53 PM
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Then you could try what Curtis73 said. Can you get at it to drill? I've never had any luck with easy outs though. Get it as hot as you can with what you've got and use the wax trick. Might work.
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Old 05-01-2011, 09:55 PM
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cant get a drill in the area to drill it so looks like a trip to the machine shop to get it fixed...thanks guys
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Old 05-01-2011, 10:16 PM
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i found a 1995 Ford pickup 302 EFI complete engine ready to run - $350 ..guy said i can hear it run..wondering if the heads would work on my 84 302 with a alum carbed intake..
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Old 05-02-2011, 09:35 AM
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Should work, but get the casting numbers. They might be vastly different heads; chambers, ports, valve sizes, etc.
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Old 05-03-2011, 02:10 AM
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the casting numbers are f3zeaa and the guy wants 300 bucks for them
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Old 05-03-2011, 06:19 AM
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$300 for a set of common iron Ford heads is outrageous. $350 for a nice running engine is OK. And yes, they will work on the '84. The major caution is to make sure that it has the right accessory bolt holes. As far as the intake fitting - yep, it will work. You might have to "play" some games with intake gaskets but about 90+% of OEM Fords will use a Fel Pro Q1250 or Q1262. Head gaskets - Fel-Pro10111 or 10112.

....or you could take that existing head to a machine shop and have them EDM that broken bolt out. Even a non-automotive shop could have that machine.

As far as wicking candle wax or welding nuts on - while it seems to work for others - my luck doing it is less then great .

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Old 05-03-2011, 12:43 PM
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I think if you have no other choice, the cheapest way would be to take the head off and take it to someone. I've tried the nut welding trick and it's worked well. If you can line up a welder for 5 minutes, what can it hurt? You're no worse off than you are now if you ruin the head, if you're going to buy a head anyway. Not long ago I dragged my little 110 welder over to my neighbours garage. He had the same problem as you with an intake bolt. Just barely tacked the nut on and it came out by hand!
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Old 05-03-2011, 03:06 PM
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Before you go pulling the head try heating and cooling it a few times. This will usually break the bond and it will come out. The wax trick also works well. If you can get to it with a small chisel or punch, give it a few taps after you heat it. Usually once is breaks free it will spin right out.
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Old 05-03-2011, 07:34 PM
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If you're going to pull the head anyway - and Ezee outs are anything but - I find I can usually clean out blind ending holes in cast with an oxy acetylene torch.

Heat it - slowly - along with the surrounding area to just under cherry red and give it one quick blip on the oxygen. If you get it right, bolts have a lower melting temperature than cast and it will clean right out. If not, the bolt will be annealed to soft enough for a drill.
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Old 05-03-2011, 09:01 PM
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I know you don't have enough room for a regular drill but how about an anglehead drill? I always use left hand drill bits, often they will bring the broken bolt out. If you use a regular drill bit and the bolt spins, it will jam it to the end of the threads and make it much harder to extract.
Easy outs are almost a last resort. The square kind that you tap in will sometimes work. The twist in kind are junk and are very brittle, break one of those off in there and you have a real problem.
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Old 05-03-2011, 10:15 PM
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Quote:
Originally Posted by hddave1
dont have a welder and dont think i could weld a nut on it without welding to the head...
Very easy and fast, you use a wire feed and weld inside the nut, not around the outside, it will come right out, bet on it. You must know someone with a small MIG welder, if not, put an ad on Craigslist, there are people out there itching to help fellow rodders...
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