In a message dated 97-06-11 03:42:11 EDT, JANPETRO@aol.com writes: > While removing a very rusted exhaust pipe I have broken one of the bolts with > only a very small part of it still sticking out. What are my prospects? > Drill? > Heat? > Removing the Head? I doubt that a drill or heat will work. I had this problem with an engine out of the van and I was completely unable to remove the broken bolt with normal tools. I even broke off the (not so)easy-out inside the broken bolt. I took the whole engine to a machine shop that specializes in removing broken bolts/taps/easy-outs and they used a laser to remove the remains of the bolt and easy-out and installed a stainless steel "insert" with new threads the same size as the original. My advice is to call around and find a shop with this kind of tool and experience and pay them to do it. I wish I could get back all the frustrating hours I spent on this myself. Removing/installing the whole engine might be easier for you than doing the same on a head if you're talking about a Vanagon waterboxer engine. Good luck, Jim Davis 87 GL Syncro 88 GL Wolfsburg
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