Broken bolt in thermostat housing....

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Ok I friggin snapped the bolt that holds my water neck to my water pump housing. I'm apparently not a very good machinist, I tried using a bolt extractor kit for harbor freight and probably made it worse.

Any advice on getting it removed without buying a whole new water pump housing? My plan would be to drill out the hole larger and run a new bolt and nut to mount.

1964 Chrysler 300k with 413 AC is the car.

Screenshot_20200928-133028_Gallery.jpg
 
Two choices.

1. Remove water pump housing and take it to a machine shop. They'll make quick work of removing that bolt.

2. Remove water pump housing, replace with a new unit. Not only do you have a new unit that will last your for many years (think: shaft seal leakage), it will have a nice new bolt hole for ya.

Your third choice....continuing to hack away at it while leaned over your engine compartment is not a good choice. I know the Utoob vids make it look easy, but often it simply isn't.
 
Thanks Trace, was trying to avoid the inevitable. Lol

Plus this housing is HARD to find
I know that "inevitable" feeling. Don't we all? :( But the good news is you knew in your bones it was inevitable, so you're home free in that regard. :D

I would just hate to see you REALLY ruin it by continuing.
 
Ok I friggin snapped the bolt that holds my water neck to my water pump housing. I'm apparently not a very good machinist, I tried using a bolt extractor kit for harbor freight and probably made it worse.

Any advice on getting it removed without buying a whole new water pump housing? My plan would be to drill out the hole larger and run a new bolt and nut to mount.

1964 Chrysler 300k with 413 AC is the car.

View attachment 405506
If the stud is sticking up a bit place a nut on it and weld it to the broken piece. It should remove quite easily then.
 
If the stud is sticking up a bit place a nut on it and weld it to the broken piece. It should remove quite easily then.

Load it up with Break Fee. You did not get the extractor centered which is a must for any extractor to work properly. Hint: Harbor Freight is not a good choice. Get a good one from Ace Hardware. Drill a pilot hole completely thru the broken stud and fill it to the brim with Break Free or some other good penetrating oil and let sit overnight. It should then come out.

Dave
 
2. Remove water pump housing, replace with a new unit. Not only do you have a new unit that will last your for many years (think: shaft seal leakage), it will have a nice new bolt hole for ya.

The pump is a separate piece from the housing.
 
This looks like the perfect candidate for that type of repair. Weld a washer on, then a nut.


That’s a great demonstration of how to do it. By using a washer you can still make the weld even if the broken piece is flush or slightly lower. The heat helps to loosen up the frozen stud and they come out easy. Done this many times but you have to take care. Good luck.
 
G'Day People,
Just a Small Point and from what I can see it would not have been Helpful in this Circumstance.
Over here in the Land of OZ I worked in the Wrecking Industry for a Number of Years, It was Not Uncommon for some Poor Ford Owner to walk in wanting to buy a Dizzy for his V8 Ford & he would bring with him the two broken halves of his old Dizzy.
Don't know if it was common in the States but the Clevelands' especially had the habit of "Welding" the Aluminium Dizzy Body to the Block and fellas would end up using two tyre levers trying to remove them. They had tried EVERYTHING Penetrating Oil, Gas Axe Etc, Etc,. All without Success and Often with somewhat Disastrous Results.
(We actually sold quite a few Dizzy over the years) Eventually we came up with a Simple Solution of building a Clay Dam around the base of the Dizzy & filling it with Eucalyptus Oil. After about three Days of soaking you could usually grab the Dizzy with both hands & simply twist it out. As I said maybe not for this case but keep it in mind.
Regards Tony.M
P.S.
I recently purchased a Aluminium BB WP Housing over here for A$35. Super Cheap! But then a Friend pointed out there had been a Batch of "Porous" housings on the Market. This didn't alarm me I Figure that a Good Internal Coating of the right paint should eliminate any Problem. (All Fingers & Toes Severely Crossed, Let me know if you think I'm Wrong!)
 
Hmm is it actually a flanged, so that you could just drill it open and use bolt and nut? That's what i would do in a heartbeat if I didn't have a welder. With a welder and washer & nut trick the steel bolt should come out easily from cast iron manifold. Just use as much power as possible to really heat that bolt during welding.

I just removed broken bolt from newer 360magnum aluminum intake manifold by welding. Took two tries with welding and loads of penetrating oil, banging, patience and wigling back and forth. Usually a steel bolt frozen in aluminum is a lost cause but this time I got lucky.
 
Hmm is it actually a flanged, so that you could just drill it open and use bolt and nut? That's what i would do in a heartbeat if I didn't have a welder. With a welder and washer & nut trick the steel bolt should come out easily from cast iron manifold. Just use as much power as possible to really heat that bolt during welding.

I just removed broken bolt from newer 360magnum aluminum intake manifold by welding. Took two tries with welding and loads of penetrating oil, banging, patience and wigling back and forth. Usually a steel bolt frozen in aluminum is a lost cause but this time I got lucky.


Yeah the welding would be ideal, no welder to use tho. Yes, my plan would be to completely drill it out and use a different nut and bolt. Any suggestions on what kind of bit? I can seem to drill through this thing with my 1800rpm lithium ryobi drill ‍♂️
 
Yeah the welding would be ideal, no welder to use tho. Yes, my plan would be to completely drill it out and use a different nut and bolt. Any suggestions on what kind of bit? I can seem to drill through this thing with my 1800rpm lithium ryobi drill ‍♂️

You should just bite the bullet and remove the cover, take it to a machinist and get it repaired properly. Also, extractors never work in a situation like this. You always end up drilling the hole off-center, or you drill the pilot hole properly, but end up breaking off the extractor when trying to remove the broken bolt, and then you are really screwed.
 
You should just bite the bullet and remove the cover, take it to a machinist and get it repaired properly. Also, extractors never work in a situation like this. You always end up drilling the hole off-center, or you drill the pilot hole properly, but end up breaking off the extractor when trying to remove the broken bolt, and then you are really screwed.


Yeah, this is the unfortunate truth lol.
 
But just think how nice you'll feel when it's all done correctly, maybe some paint and other grooming of the engine.....

Yeah I agree, and I'm in the process of cleaning everything up, but I got a big move coming and trying to throw everything together quickly as a temporary solution. Time is of the essence.
 
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