Shark Attack

thats an "aw f&^ck" if i ever saw one

Bill Ball

I don't know how many times and how many people have posted here "DON'T USE E-Z OUTS OR SIMILAR BOLT EXTRACTORS!" What happened to you is almost guaranteed.

However, diamond-tipped Dremel bits will make quick work of the extractor. They are not expensive, and if you are careful not to over heat the bit (drill no more than 30 seconds at a time, low pressure, watch for the tip to start glowing red) one or two will cut the extractor out. I used them on a busted tungsten carbide tap, and had it out in less than 15 minutes.

Get Dremel 7105, 7103 or look for a kit of such bits in different sizes. Local hardware stores should have them.

Stan.Shaw@Excell.Net

If you decide to pull the crossover, you might want to clean it up, then maybe pull the intake and do the same, not to mention changing all the rubber parts. So long as you go that far, you could pull the intake and cam towers to get them powder coated. As long as you are in there that far, you might want to consider pulling the heads and changing head gaskets, maybe do a valve job while you are at it. Of course you could consider upgrading to Euro S parts, adding headers and going with either forced induction or stroking & boring the motor too.

If that isn't enough to turn one small project into a big one, I am sure the 928 community can come up with other suggestions.

My wife sometimes ask me if I am ever going to put ANY of my cars back together....

BC

I get that daily.

checkmate1996

This has worked for with a good degree on success. Here's my order of stuff when I know I'm up against a stubborn bolt.

- PB Blaster or KROIL and Wait for 15-20 minutes
- HEAT 3-4 minutes at a time depending on the size of the bolt, where, etc
- Larger ratchet for more leverage
- Repeat until out

If you break a bolt,
- I actually used the dremel tool to bore out the bolt and then use an E-Z Out.
- In your case, I would take off the water bridge as suggested, ( LOTS OF PB BLASTER OR KROIL) becuase those bolts never get removed. Let it soak for days.
- Take over to a welder shop and have them weld on a piece of stell onto the bolt and it just backs right out....don't ask on how on know this one either!

GL - We've all been there!

Bret928

Wow. Sounds like a lot of work. Talking to 928 int they have a new cross over for about $100 not counting the gaskets, O-ring and any bolts needed I still might be cheaper off going that route than taking it to a local welder or a machine shop. Either way if I cant get the broken bolt out I might still have to pull the crossover no matter what.

So for now I'm going to look into the diamond dremel bits first and start treating the crossover's bolts now just in case.

checkmate1996

Other ideas:

If worse comes to worse, I can see if my buddy could take the bolt out for you...just pay for shipping the waterbridge back and forth. I'll ask tonight...

I have a used waterbridge off of my 4.5 L I could sell you also...

SwayBar

There is absolutely no need to buy a new cross over; there are probably 1000's of used ones, available, really cheap...

Bret928

Always willing to take a used one off of someones hands should I need it. Just wanted to confirm that I had some options before I got too agressive with removing the broken bolt.

rixter

Bret,
I'm sure I have this at the house, but I won't get to it until after SITM... if you can wait til next week you'll only have to pay shp

928SS

don't forget powder coating or polishing everything you touch, can't have a dull looking motor

I just wanted a hot dog on my bbq last thursday night, but it was dirty. by sat night I'd pressure washed and wire brushed everything, replaced the burners, igniter & heat diffusers... went to fire it up - no propane. by sunday I'd solved that one w/a new spare bottle and finally had some dog's on the grill... then a rennlister called me to talk about 928's - 40min later the dogs were cold...

the 928 slope is inescapable - maybe you should just pull the motor and stop fighting it while you are waiting for your new motor parts - you can have a hot dog on the bbq. hahaha

Bret928

Apparently, I have nothing but time. But thanks I should know by next week if I need it or not.

I’m just annoyed that I was *one* bolt away from driving the car.

hacker-pschorr

If you are going to yank it anyway, just JB weld it back on until you receive the new parts

Bret928

LOL! Yeah you laugh Hacker, but cheap-**** Pollock in me thought about that a couple of times before reason kicked in.

Actually it was a 6-pack of Newcastle Brown Ale that made any attempt at hand tools in a dark garage a dangerous endeavor.

hacker-pschorr

JB weld would work just fine. I would let it cure for at least 24 hours. I used it as an emergency oil drain plug fix few years ago (stripped threads). Worked like a charm until I had a chance to swap pans.