robp823 Posted September 2, 2009 Share Posted September 2, 2009 Ok...So one of the salesman says his buddy just bought a 95 f-350 powerstroke and it has a big exhaust leak and asks me if i would take a look at it.So i say yes and i have him bring it in the shop after hours.So i pull it in and sure enough its got a huge exhaust leak at the left side manifold.A closer look shows that the last 2 bolts closest to the up pipe are broke off flush and there is about a 1/4 inch gap between the exhaust port and manifold.So i agree to fix it for him.So i go to his garage to get wrenching on it and once i get the inside fender well out i see that not only is this thing rotted to all hell but there is nothing left of the heads of the bolts.In fact you cant even tell where they are.Its like they have become one with the manifold they are rotted so bad.So out comes the torches.I get the manifold off and i have about a half inch of bolt showing for all exhaust bolts.So i think easy cruising ,get my stud extractor out and start wrenchin some more.After 2 broken stud extractors i was only able to get 4 of them out.So now i say to myself, ok just grind down whats left of them close to flush with head and drill the rest out.So i start grinding away and sure enough i lose my footing and end up taking material away from where the manifold seals off the port and its to much for the gasket to compensate for.Now im pissed.So heres my question.Can i put some weld in there to fill it in sothe manifold will sit flush against the head???Also this is the worst one i have ever had to do...If for some reason i cant these out with an easy out what is my last resort???Any help appreciated.I sure got myself in a pickle here. Quote Link to comment Share on other sites More sharing options...
Aaron Posted September 2, 2009 Share Posted September 2, 2009 What about welding a nut or a bolt to what's left of the bolt? Turn the amps WAAAAAAAAAY up my friend. Welding to cast doesn't generally work all that great...are you using a steel exhaust gasket or a composite? Quote Link to comment Share on other sites More sharing options...
robp823 Posted September 2, 2009 Author Share Posted September 2, 2009 composite Quote Link to comment Share on other sites More sharing options...
Brad Clayton Posted September 2, 2009 Share Posted September 2, 2009 Just buy the truck then you won't have to fix it. Quote Link to comment Share on other sites More sharing options...
DwayneGorniak Posted September 2, 2009 Share Posted September 2, 2009 I agree with Arron. You shoulda welded a nut to the bolt and shoulda also let them bastards soak with tuneup cleaner or weasel piss for a freakin day with frequent replenishing of the weasel piss to help loosen the carbon up that gets trapped in the threads. I've been there. But now that there is a gouge in the metal surface, I'd say that heads a fucked for sure. May the force be with you. Quote Link to comment Share on other sites More sharing options...
LARRY BRUDZYNSKI Posted September 2, 2009 Share Posted September 2, 2009 Loctite makes a product you might be able to use. I'm not one for fixes like this but it sounds like you are doing this guy a favor. It's called Quick Metal #66040 We have used this in certain circumstances to repair minor imperfections on mating surfaces that won't be coming apart. Usually on obsolete parts that we can't get replacements for. Good luck Quote Link to comment Share on other sites More sharing options...
GregKneupper Posted September 2, 2009 Share Posted September 2, 2009 Man I am glad that I live down south. I would not know where to begin to fix something like that. Quote Link to comment Share on other sites More sharing options...
mchan68 Posted September 2, 2009 Share Posted September 2, 2009 Man I am glad that I live down south. I would not know where to begin to fix something like that.That statement reflects perfectly, on why working on vehicles from the States is an orgasm to me. I don't think I ever get vehicles that are five years or older that are so clean under the body you can eat off them, or NOT needing the use of a flame wrench to get apart. American customers tend to throw GENEROUS tips at me too. What is this a custom I'm not aware of? Quote Link to comment Share on other sites More sharing options...
DwayneGorniak Posted September 2, 2009 Share Posted September 2, 2009 Originally Posted By: GregKneupper Man I am glad that I live down south. I would not know where to begin to fix something like that. That statement reflects perfectly, on why working on vehicles from the States is an orgasm to me. I don't think I ever get vehicles that are five years or older that are so clean under the body you can eat off them, or NOT needing the use of a flame wrench to get apart. American customers tend to throw GENEROUS tips at me too. What is this a custom I'm not aware of? I know what your talkin about. I have seen the same things many times. Damned nice trucks and they tip very well. Quote Link to comment Share on other sites More sharing options...
Keith Browning Posted September 2, 2009 Share Posted September 2, 2009 American customers tend to throw GENEROUS tips at me too. What is this a custom I'm not aware of? Oh no! He found out our secret!!! Now he must be silenced... stay right where you are Mike, some nice men are coming to visit you. Quote Link to comment Share on other sites More sharing options...
Aaron Posted September 3, 2009 Share Posted September 3, 2009 Man I am glad that I live down south. I would not know where to begin to fix something like that. Bite me? Quote Link to comment Share on other sites More sharing options...
blown99 Posted September 3, 2009 Share Posted September 3, 2009 If you have access to a stick welder you could use some nickel rod to fill the hole then grind it down. Quote Link to comment Share on other sites More sharing options...
robp823 Posted September 3, 2009 Author Share Posted September 3, 2009 Well i went back to work on the truck today and i had enough bolt left sticking out to weld a nut on them.So i gave it a shot.The bolt started to turn then snapped flush in the head.The weld held but the bolt didnt. What the fuck.So i didnt even bother trying any of the other ones.Good idea though Aaron i will def do that next time im in a situation like this.Im sure it usually works but this is an out of the ordinary situation.Ive never seen a truck this bad with rot on everything underneath.Larry i picked up PCF, its rated for 500 degrees and filled in the part where the head was messed up.Ill give it a shot but you are right this guy new exactly what he was getting into with this truck and yes im doing it as a favor.I think he only paid 2500.00 for it.Its an old Jersey township plow truck.Just to give you an idea how bad this truck is when pulling out the inner fender well part of the fender came with it! The oil cooler looks like if you press on it hard enough with your finger it will go right through it.Right now im guessing my last and final option here is drill out the broken bolts to the same size and retap them or find a cylinder head.The only good thing about this whole situation is that the guy is pretty mechanically inclined and isnt rushing me or nothing.So he pretty much knows what a pain in the ass job it is. Quote Link to comment Share on other sites More sharing options...
Jim Warman Posted September 3, 2009 Share Posted September 3, 2009 Not a solution... just some advice. Every time I set out to save somebody one dollar... it cost me 10 Quote Link to comment Share on other sites More sharing options...
Keith Browning Posted September 3, 2009 Share Posted September 3, 2009 Its an old Jersey township plow truck. Knowing EXACTLY the implications of this statement I would have run from the truck. I think the guy that bought the truck should be asking himself "what did I get myself into?" Quote Link to comment Share on other sites More sharing options...
robp823 Posted September 3, 2009 Author Share Posted September 3, 2009 Yea very true next time ill just have to walk away Quote Link to comment Share on other sites More sharing options...
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