Man how I love the binding properties of steel bolts in aluminum heads. This cam cover bolt was seized so severely in the head that despite the most gingerly technique the bolt still broke. Then, while drilling out the remaining stud, the drill bit broke flush with the surface of the head making it nearly impossible to grab the remainder if the drill bit. Then, in the process of trying to work the drill bit out the boss breaks off the head… MOTHER F*CKER

Oh, and there are 2 more broken bolts in this head. I've never had this problem with heads before, now I have 3 broken bolts in this one engine...

 

It is going to take some heroics to save it now.
I have never seen one I cant get out with a welder if I can get access to it, even if it is broken off below the surface.

Next time take it to a welder.

sorry buddy about it breaking off like that.

 

Thanks man. This has truely put a damper on the evening. You'll have to teach me the welder technique so I don't waste any more heads.

 

No sh*t, that stinks... sorry. Take a load off and have a beer or JD.

 

Bill, my condolences brother.

 

There's enough meat left to drill and tap it deeper for a longer bolt. It's outside the gasket sealing surface so you should still be okay. All is not lost.

Worst case, JB weld a stud in there and use a nut to tighten down the cam cover.

 

Be happy to teach you that, if you can weld with a mig we can do it over the phone.
The really hard ones are a broken off stud that is down in a hole a few inches, that takes a stick.

 

Or just fix it the right way, weld up the broken part back on, then weld the hole up, drill, and tap.

 

that will buff right out. . Actually , I agree. all is not lost. its only a seal area. Im sure you can find a way to seal that up on the heads

 

Some days I take things to the machine shop. They say "$1 a minute." I say "God bless you."

 

Good feedback guys - thank you. This was pissing me off when I went to sleep last night and it was pissing me off when I woke up in the morning.

 

I think its repairable, I have a good aluminum welder and he fixed things I thought were toast. He welded the piece back on, then tapped it.