Breaking Bolts

Hi everyone...

I'm a new OC member and new 928 owner.

Just picked up a 79- 928! The previous owner was working on a restoration, but handed it over to me. It's not running now, but it was driven into the garage 2 years ago. The interior is out, and the all of parts from the top of the engine has been taken off. The heads, water pump, timing belt are all still attached. I have degreased the engine.

I'd like to put the engine back together, changing parts that makes sense now, e.g., water pump, timing belt, etc. and get the engine running.

My first challenge is experiencing bolts breaking as I try to take them out. I'm currently working on the housing that the Warm-up unit sits on. One bolt on top and one that attaches this housing to the block were already broken. I PB blasted and then tried to EZ out the smaller bolt on the top of the housing. Unfortunately, the EZ out broke. I also tested one of the Hex head bolts that attaches this housing to block. It's solidly torqued down.

Do you folks have any advice on how to deal with this tough bolts? I'm tempted to put some heat to them, but could use a "voice of experience" so that I don't make matters worse! This feels like this will be reoccurring theme a I take this off this car!

Any advice would be appreciated!

joe

Attached files [img]media/attachments/17504=2548-boltsToBlock.jpg[/img] [img]media/attachments/17504=2547-brokenBolt.jpg[/img] [img]media/attachments/17504=2546-Joe'sPorsche928.jpg[/img]

I am not a fan of easy outs; I prefer reverse drills, as I've had problems with easy outs too. Also, be careful with heat up there due to proximity to fuel sources. If the fuel is all out, heat will work. Try the reverse drills after lots of overnight soaking with a good penetrant.

PB Blaster is a good penetrant. Apply the penetrant, rap on the fastener with a hammer (corrosion is brittle), reapply, wait a day or two, reapply, tap again, reapply, wait...

Try to loosen, then try to tighten (only go for a tiny bit of movement), repeat.

A small impact wrench sometimes will break it loose (corrosion is brittle).

Easy-outs rarely work.

Sometimes a left-handed drill bit will remove a broken fastener. If you have a stub sticking out, try to find a nut that can serve as a drill guide. MacGyvering a drill guide can save a huge amount of trouble.

Good luck!

heat, lube, heat, lube

Thanks Ed and Wally!
I suspect that I may end up using all of these options during this restoration! EZ outs have worked for me before, but I've never worked on a 35 year old aluminum engine before.

I do have a follow-up question about using heat on a 928 engine.
Ed, there no fuel in the area now, so that shouldn't be an issue.
I'm just a little concerned with using too much heat for an aluminum block.
I was thinking of using a propane torch. I can measure the temperature, but how hot?
Any guidance here?

I'll pick up some reverse drills this week!
Thanks

Joe

Brad,
Thanks too!
Same question to you. How hot?

Joe