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nowivdunit · Joined: 08 Apr 2006 Posts: 6

I am new and have been reading this board for advise for a while now. But now I need help as I can not find it in my searches. Seems like I have gotten myself into a very difficult problem. I was torqueing my head bolts and one snapped off. How can I fix this? Oh my car is a 1982 924 turbo.

Benino · Posted: Sat Apr 08, 2006 3:55 am Post subject:

wow. I hate that feeling.

I can't think of anything short of pulling the head. if the bolt is snapped off completely in the block then drill and tap to slightly larger size. If it's sticking out a little bit maybe you could clamp or weld something to it and unscrew it.
_________________
1980 Porsche 924 N/A USA
1980 Porsche 924 turbo USA
1987 Porsche 944S USA

Raceboy · Joined: 01 Mar 2004 Posts: 2327 Location: Estonia, Europe

If the bolt is even with block, then you could weld something thinner on it and get that bolt.
But the head has to be removed for that, not a doubt.
_________________
'83 924 2.6 16v Turbo, 470hp
'67 911 2.4S hotrod
'90 944 S2 Cabriolet
'78 924 Carrera GT replica
'84 928 S, sold
'91 944 S2, sold
'82 924S/931 "Gulf", sold

'84 924, turbocharged, sold.
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moone924 · Joined: 05 Feb 2003 Posts: 868 Location: Douglas Wyoming

it shouldn't be hard to remove, but you'll probably have to take the head off depending on where it's broken. If it's just out of reach, try center punching it and drilling a hole in the center of it, then using a broken bolt/screw extractor. like these ------>

http://www.mytoolstore.com/hanson/extractr.html
_________________
Ryan Moone

Always shopping for a nice s2 931 to baby.
New philosophy : one car project at a time.

Smoothie · Posted: Sat Apr 08, 2006 4:51 am Post subject:

If it's snapped off inside or at the surface of the block, I would start by trying an extractor - drill just the bolt and use an extractor on it. Don't drill out the whole hole unless the holes' threads are damaged or as a last resort if the stuck piece won't budge by the weld or extractor methods.
_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

nowivdunit · Joined: 08 Apr 2006 Posts: 6

It broke about 3 threads into the block. Does anyone make a long extractor like 4 or 5"?

-nick · Joined: 16 Nov 2002 Posts: 2699 Location: Cambridge, MA

Even if there was an extractor that long, you would still need to drill a pilot hole for it. Which means metal shavings.

Head has to come off, no doubt about it. You'll also need to use a new headgasket since yours is at least slightly compressed. And don't forget to write down the torque settings and use a quality torque wrench!

Don't worry too much, these things happen

nick

nowivdunit · Joined: 08 Apr 2006 Posts: 6

Thanks for that encouragement. I already spent all day yesterday worrying. My heart sank to the garage floor when it happened. I do not think I overtightened it but maybe my torque wrench is out of calibration. I was on the final tightening sequence when it snapped, maybe 65ft-lbs. When I first loosened it, it made a loud snapping noise and I thought I broke it then. So I removed it for inspection and all seemed OK. But maybe it got stressed at that point. This was done on a cold engine. Maybe I should have done it on a warm engine.

Smoothie · Posted: Sat Apr 08, 2006 5:52 am Post subject:

The problem with using an extra long drill bit is it wouldn't center itself and would end up drilling through the threads. You'd have to come up with and use a guide bushing in the hole to keep the drill centered. -Then come up with an extra long extractor, maybe weld a length of rod to the end of a regular extractor and with all this hope neither the drill bit or the extractor breaks while you're at it... Maybe possible, but it's all up to you which is more fun - trying something like that or removing the head.
_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

nowivdunit · Joined: 08 Apr 2006 Posts: 6

Well, I've got some good news to report. I was able to remove the bold with the head on. I soaked it in penetrating oil for 2 days. I bought a set of titanium left hand drill bits and a drill bit extension and made up a brass sleeve from a barbed coupling to keep it centered. I had drill out the extension so a 5/16 bit would fit. Then with a reversible drill, I started drilling and it came out quite easily. The bolt was stretched 1/8 and snapped about 3 threads above the block. Thanks for everybodys help.