elanman

Lifted my head for the first time and broke one of the coolant channel allen head bolts. It remains in the block, it broke at the head of the allen bolt. I have tried heat with penetrating oil and gripping(and turning) what remains of the bolt but it wont move
Anyone removed this broken bolt in situ sucessfully? Welding nut on with MIG welder? Induction heater? Easy with the block out of the car EDM etc

V2Rocket

I had one EDM'd with block still in car, was $175 and a tow.

elanman

May have to just put it together with the broken bolt in place. Maybe one bolt and the cantilever load from the head will be enough to seal the coolant
I see a few have done exactly that

931guru

delete

V2Rocket

well...for the record the 944S 2.5 16v only uses one bolt there (actually a stud in the block with a nut)

odonnell

Get some Irwin extractors - the ones made for internal drive fasteners:



Hammer on the closest size tool onto the bolt and pop on your breaker bar. These things have saved my *** so many times. I think the whole set is under $20 and they're even impact rated. You can get them at places like Lowes and Oreilly.

elanman

Came out easily with an induction heater, just monitor the temperature of the block Aluminum. It went from impossible to finger tight after heating .Lots of penetrating oil probably helped over the week. Amazing tool -one for the tool box and a few beers for the man that I borrowed it from

Ky944TurboNewbie

I feel your pain. That bolt nearly killed me. Repeated heat cycles and penetrating oil finally got mine. Glad you got it out.