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  #16  
Old 04-06-2006, 12:49 PM
Cabernet red, actually
 
Join Date: Jan 2006
Location: Willamette Valley, OR
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Quote:
Originally Posted by krs
Ralph,

Don't buy the kit until you know what you're going to have to deal with. A bolt extractor like that won't do any good for a flush break. You really need to carefully review the situation before taking any action at all, and Wayne above has posted most relevant cautions although I would be very hesitant to wield a torch in that area, particularly with aluminum involved. Aluminum does not heat to the old familiar colors of steel and even cast iron so it's quite possible to bring it to the point of destruction without prior warning indicators. A broken bolt is not always an easy thing to remove the remainder of, and it is almost always a wonderful opportunity to do further even more extensive/expensive damage than it alone has brought forth.
There is probably an inch or more of the bolt that's grippable. Is that enough info. to know whether the kit would be useful or not? Does anyone know?

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1985 300D Turbo, CA model
248,650 miles and counting...
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  #17  
Old 04-06-2006, 03:04 PM
apache's Avatar
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Location: North Central MO, USA
Posts: 91
It sounds as if you have plenty to grip on to. Bring a bolt of the same size to the store with you to make sure that you buy a set with the correct size extractor. I bought a Sears set of all of the odd sized extractors with a case that is big enough to hold the even sizes also. My set cost $19. I will drop another $19 to buy the even sizes someday although I have lucked out and have been able to use the odds for everything that has come up so far. This is one of my best investments I have made in tools. Even if it doesn't work for you this time, you will be glad you bought it someday.

Good luck and let us know how it worked out. Jim
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  #18  
Old 04-06-2006, 03:14 PM
Cabernet red, actually
 
Join Date: Jan 2006
Location: Willamette Valley, OR
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OK, I went to the store, looked at the product and paid $20for the even sizes, which will fit my 8 mm bolt, or so says the packaging. I will try it out, probably this afternoon...

I've been unable to find an 8 mm stud to replace the broken one so far, I think I might try pushing an 8 mm bolt through the bottom (if I can reach down there) as a temp. fix, since this will hold as well as the stud once I get the nut on.
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1985 300D Turbo, CA model
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  #19  
Old 04-06-2006, 11:38 PM
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Glad to hear that Roamer is safe. That would have been devastating.
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  #20  
Old 04-06-2006, 11:59 PM
t walgamuth's Avatar
dieselarchitect
 
Join Date: Apr 2005
Location: Lafayette Indiana
Posts: 38,613
if you find a bolt

measure carefully. you want to have the same amount of thread biting into the aluminum housing. if the threaded area is too short you will either lack sufficient gripping power to keep it sealed or strip out the aluminum threads in the housing (dont ask how i know). if you get a bolt that is too long be sure to use washers to get the pressure on the top of the cannister.

you need about two to three times the length of thread with a steel stud in aliminum to match the strength of the steel nut on the steel threads.

you also could buy a bolt that has too long a thread and just cut it off and use it as the stud. this assumes that the threads into the housing and the nut are the same.

proceed with care. the oil pressure is contained by this and if you get it wrong you can ruin the engine in a heartbeat.

tom w
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..I also have a 427 Cobra replica with an aluminum chassis.
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  #21  
Old 04-07-2006, 08:52 AM
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Location: Mount Holly, NC
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woha! if you have an inch of bolt sticking out

just use channel locks to remove the bolt. the sears bolt extractor just cuts into the top of the bolt. channel locks will hook to the sides of the bolt, don't use a huge set, or you will end up breaking the bolt off again.
John
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  #22  
Old 04-07-2006, 11:48 AM
Cabernet red, actually
 
Join Date: Jan 2006
Location: Willamette Valley, OR
Posts: 503
Thumbs up Success!

The bolt removal tool worked beautifully! It went down on the bolt about a 1/2 inch and after that removal was simple, all I had to do was turn the wrench. It just took a couple of minutes once it started moving. Amazing. As broken bolts go, I'm lucky.

Tom W, thanks for that info. about what I should do with the new bolt. Of course, I put a new one in before I read your post. Here's what I did: I got a long 8x1.25 mm bolt, which the nut fits perfectly around, and I screwed the nut on to the bolt before screwing the bolt into the housing.

My original plan of sticking the bolt through the bottom was ludicrous; that never would have happened without taking things apart, and when I looked at it I realized it was just as effective from the top.

Anyway, I screwed the bolt on pretty good, I'm sure there's an inch or more (likely more) inside the housing to hold it in place. When it didn't seem to want to turn anymore and appeared tight in the housing, I screwed the nut down on the housing, holding it tight.

I've kept a very close eye on the oil pressure and so far, so good. I've inspected for leaks and haven't found any. I'll definitely check the oil level and look for leaks again later today, as well as checking for tightness of the nuts and bolt on the housing.

As for now, the car seems to be running great. I owe you guys a lot, and Mr. Craftsman, too. That guy makes some great tools! Seriously, though, this really had me banging my head against the wall (mostly proverbially, I only actually banged it a couple of times) and once again it was the forum to the rescue.
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1985 300D Turbo, CA model
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  #23  
Old 04-07-2006, 01:51 PM
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Join Date: Aug 2005
Location: Palmdale/Ventura, CA
Posts: 813
Congratulations.

Quote:
Originally Posted by Maroon 300D
My fiancee will only tolerate so much car work and I'm already over that line.
- and - My dog was nearly run over by a steam roller later in the day.
Car fixed, fiancee hopefully still around, dog safe.

Sounds like the makings of Country-Western Hit Song.

It is great that this one worked out for you.
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  #24  
Old 04-07-2006, 07:44 PM
t walgamuth's Avatar
dieselarchitect
 
Join Date: Apr 2005
Location: Lafayette Indiana
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good job

you figured it out on your own.

the best way

tom w

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..I also have a 427 Cobra replica with an aluminum chassis.
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