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Old 12-12-2011, 09:55 PM
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how do I remove a rounded bolt on 305 manifold

Hey you hotrod pro's I have been trying to put a 350 in my 79 elk for longer than I care to admit. I am over my head but because of cash shortage here I am. My latest problem is a difficult bolt on the intake manifold. Anyone who knows the Chevy 305 will know the area that is giving me fits. Because of the lack of space I am not able to get a good fit with any tool and round off a couple of corners of the bolt. There is not much room because of the casting of the manifold. Can anyone give me some help on how to get this last bolt out?

Seasonís greetings

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Old 12-12-2011, 10:08 PM
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I had a similar issue a couple of years back, I used a hammer and punch, drilled a small divot in the side of the bolt and tapped it loose. Someone might have a better method, but at the time, with my frustration level being what it was, it did the trick and let me move on
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Old 12-12-2011, 11:05 PM
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rounded

if you'v got a mig welder zap a bolt or nut on onto broken 1 and undo with single hex socket [slowly undo] .. peter
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Old 12-13-2011, 02:10 AM
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I have used a die grinder to cut a straight slot across the top and then used a big screwdriver bit in a rachet.
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Old 12-13-2011, 07:48 AM
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If you have room to get a grinder in there you can grind off the head of the bolt and slide the manifold off then use vise grip pliers on the remaining part of the bolt
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Old 12-13-2011, 09:02 AM
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heat and oil

I like to heat them up a few times and squirt penetrating oil, cool down then use the other methods posted .
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Old 12-13-2011, 09:08 AM
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Sears sell a "Gotor-grip" socket. Although a cheezy as seen on TV item, I have found it works well on rounded bolts. It's about $10 and pretty usefull.

Otherwise all of the tips above work well. I prefer cutting a slot in the top for a screwdriver bit. Just make sure to blow the area clean before llifting off the manifold so no grinding dust gets in the engine below.
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Old 12-13-2011, 02:25 PM
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Post subject: Penetrating oil test.

--------------------------------------------------------------------------------

Penetrating oil test.
--------------------------------------------------------------------------------

Penetrating Oils Compared

Machinist's Workshop magazine actually tested penetrants for break out torque on rusted nuts. Significant results!

*They arranged a subjective test of all the popular penetrants with the control being the torque required to remove the nut from a "scientifically rusted" environment.*

*Penetrating oil ..... Average load*

None ..................... 516 pounds
WD-40 ............. 238 pounds
PB Blaster ............. 214 pounds
Liquid Wrench .. 127 pounds
Kano Kroil ............ 106 pounds
ATF-Acetone mix....53 pounds

*The ATF-Acetone mix was a "home brew" mix of 50 - 50 automatic transmission fluid and acetone*
*Note the "home brew" was better than any commercial product in this one particular test. A local machinist group mixed up a batch and all now use it with equally good results. Note also that "Liquid Wrench" is about as good as "Kroil" for about 20% of the price.*
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Old 12-13-2011, 09:10 PM
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Quote:
Originally Posted by low_and_slow
Hey you hotrod pro's I have been trying to put a 350 in my 79 elk for longer than I care to admit. I am over my head but because of cash shortage here I am. My latest problem is a difficult bolt on the intake manifold. Anyone who knows the Chevy 305 will know the area that is giving me fits. Because of the lack of space I am not able to get a good fit with any tool and round off a couple of corners of the bolt. There is not much room because of the casting of the manifold. Can anyone give me some help on how to get this last bolt out?

Seasonís greetings
The bolts you speak of are in the center of the manifold correct?, first clean all the gunk out from around it.
Next take a 6 point box box wrench and try and get on to it, if not often you can use a good 6 point socket and a extension that has some slop or a flex tip on it, if the carb is off.

Last tip try using a 14mm wrench or socket its just bit smaller than 9/16
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Old 12-14-2011, 09:42 PM
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stuburn manifold bolt on 305

Hey folks. Thanks for all your good ideas. some were on the net I found an explanation on the difference between a 16 and 8 point wrench. so I found a 9/16 with 8 points and a 3/8 drive. Thought I would breake the ratchet but it did the trick.
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