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Question on removal of 2 exhaust hanger bolts


PJGross
both buccal and lingual
490/1000


Galant VR-4 org Post #: 1246546 posted 07/08/19 12:55 PM     Remind Me!  Send Private Message   Edit Post      
So I'm getting #490/1000 back on the road. Its been on jackstands for 8 years or so in my garage.
Just finished going through oil, coolant, all plumbing, IC piping, put on the front bumper and closed the hood for the first time in that long.
Brakes are bled, new rotors/pads, and front wheels on.
I borrowed several gas cans from neighbor and a pump. Will pump out old gas, fill up with premium fresh gas.

I am re-doing the exhaust myself as the one that was "built" for me years ago was crap.

Have Megan DP that I fit to my oldschool T3/T04E FP turbo and custom O2 housing. I just fabbed a center section with a straight through muffler, and now I am going to mate it with a second hand catback pipe and Vibrant dual tip muffler.

Well, guy who worked on this car liked to rip off bolts. The very back exhaust hanger was no exception.

Both bolts are sheared flush with the frame holes.

I have a harbor freight flux core 110A welder, so it isn't very pretty and I don't think I can built up a puddle upside down to weld onto the sheared off bolts.

EZ-outs: I have snapped off too many and don't like that approach as I have never had success.

I was going to drill out the bolts through the center and use bigger bits until I just barely hit the existing threads, then retap with a 8M x 1.25 tap. Would this work?

I figured I would ask first before starting to drill. Of course I will go slow and use lots of lube...

Ideas are welcome,

-PJ



#490/1000

Posts: 1475 | From: Lake Orion, MI | Member Since: 12/05/02 | IP: (204.117.38.42) | Report this post to a Moderator

gvr4ever
Forever Member
347/1000


Galant VR-4 org Post #: 1246547 posted 07/08/19 12:57 PM     Remind Me!  Send Private Message   Edit Post      
Can't answer your exhaust question, but the tank has a drain bolt. Don't need to pump it out.



1992 Nile black w/sunroof
15xK miles. 2nd owner since 1998

Posts: 5853 | From: central Indiana | Member Since: 08/06/02 | IP: (69.174.160.34) | Report this post to a Moderator

PJGross
both buccal and lingual
490/1000


Galant VR-4 org Post #: 1246548 posted 07/08/19 01:00 PM     Remind Me!  Send Private Message   Edit Post      
Cool on the tank drain bolt. Wonder if it will loosen or not.
Thanks,
PJ



#490/1000

Posts: 1475 | From: Lake Orion, MI | Member Since: 12/05/02 | IP: (204.117.38.42) | Report this post to a Moderator

gvr4ever
Forever Member
347/1000


Galant VR-4 org Post #: 1246549 posted 07/08/19 01:06 PM     Remind Me!  Send Private Message   Edit Post      
I used mine a few years ago after it sat awhile. Just don't force anything. It should come off.



1992 Nile black w/sunroof
15xK miles. 2nd owner since 1998

Posts: 5853 | From: central Indiana | Member Since: 08/06/02 | IP: (69.174.160.34) | Report this post to a Moderator

iceman69510 Galant VR4.org Moderator
Turn Right Racing
855/2000


Galant VR-4 org Post #: 1246550 posted 07/08/19 01:23 PM     Remind Me!  Send Private Message   Edit Post      
PJ, your suggested method for removal of the old bolt and re-tapping is how I often do them. Keeping it straight down the middle is the trick. I sometimes grind the bolt remnant flatter if possible where it is, and then use a center punch to start the drill bit.

I live in your area now and work in Farmington Hills.



91 VR4 855 Nile Black
92 VR4 828 Belize Green-SOLD
91 VR4 115 Nile Black -SOLD


Edited by iceman69510 (07/08/19 01:25 PM)

Posts: 10665 | From: Michigan | Member Since: 03/05/01 | IP: (205.144.100.200) | Report this post to a Moderator

PJGross
both buccal and lingual
490/1000


Galant VR-4 org Post #: 1246551 posted 07/08/19 04:26 PM     Remind Me!  Send Private Message   Edit Post      
Wow, that's cool that there is someone else around here! We've been in Lake Orion since 2003.

I will center punch them, good call! It seems like I will have enough room to drill 'em and then retap.
I was surprised at how big the drill bit is for the 8mm 1.25 tap... I will try to use a size or two down and get the old crap out of there.


I have been really absent the board the last 12 years or so. Coincidentally my oldest is 12....

I've just decided its time to get her back on the road and do something with it. I've said it several times before, but never got this far with it!

-PJ



#490/1000

Posts: 1475 | From: Lake Orion, MI | Member Since: 12/05/02 | IP: (2601:401:4380:74) | Report this post to a Moderator

Dan D
220, 221... whatever it takes
410/2000


Galant VR-4 org Post #: 1246552 posted 07/08/19 04:51 PM     Remind Me!  Send Private Message   Edit Post      
Broken M8 bolt for something that can't get out and up on to the Bridgeport - my typical approach:

1. Spray with penetrant oil - let sit, spray again
2. Die grinder or dremel with a burr/stone/diamond depending on what's left sticking out - shooting for a flatish surface
3. Prick punch, use a light, scale, and magnifier to check if your on center - adjust your prick mark until centered
4. Center punch you located prick punch mark
5. Heat it
6. For M8 (minor diam = ~.262") use a 1/4" left hand drill and drill through - maybe you get lucky and comes out
7. Go up to 17/64 and drill through - barely kisses the threads - see if you can pick out what left without drilling any more
8. If not - re-drill M8x1.25 tap size for a 75% thread (letter H); tap with a high quality HSS tap and move on with your day

(HF left hand drill bits work pretty well for the minor cost of them)
Drills and taps - look elsewhere. Buy quality HSS for hand drilling. For through holes - gun taps (spiral point taps) are where it's at.



#410/2k

Posts: 1155 | From: Brownsburg, IN | Member Since: 02/27/01 | IP: (2601:805:c700:2e) | Report this post to a Moderator

PJGross
both buccal and lingual
490/1000


Galant VR-4 org Post #: 1246554 posted 07/09/19 11:30 AM     Remind Me!  Send Private Message   Edit Post   
So I cleaned up the exposed part, punched it, and drilled it.
Regular bits, worked way up to the size that comes with the dewalt M8 1.25 tap.

I almost grabbed the tap marked M8 1.25 that was much bigger: This is for M8 helicoils. I put red tape on that one and put it back in the box...

Anyway, drilled out the old bolts, and tapped and I think for the application it will be just fine.

However, I like the idea of using left handed drill bits for next time.

I will have to look up all the language on taps. I didn't know there were differences. Thank you for the info!

-PJ



#490/1000

Posts: 1475 | From: Lake Orion, MI | Member Since: 12/05/02 | IP: (204.117.38.42) | Report this post to a Moderator


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