chandler
chandler PowerDork
7/21/20 7:41 a.m.

I bought a 97 Dakota knowing it had a bolt broken off in the head. In 2009 the owner tried to replace the manifold and one bolt broke off. He shoved it in the garage and I pulled it out last week. 
 

What wasn't clearly discussed is that he took it to meinke and they "drilled" the bolt out - off center. The question is, can I put it in the drill press and over size drill it and put in an insert or am I better off putting a head on it? I'm in the truck for nothing pretty much so spending a little money isn't a big deal but I'm hoping to flip it so it's not a keeper...

KyAllroad (Jeremy) (Forum Supporter)
KyAllroad (Jeremy) (Forum Supporter) UltimaDork
7/21/20 7:56 a.m.

If you have the head out already I'd just take it to the machine shop and have them do it right.  Should cost less than $100 and they can clean it up at the same time.

1988RedT2
1988RedT2 MegaDork
7/21/20 9:57 a.m.

Oh, you mean "cylinder head."  Had me worried there for a minute. laugh

Stampie (FS)
Stampie (FS) GRM+ Memberand MegaDork
7/21/20 10:10 a.m.

In reply to chandler :

Got a picture?  What size bolt?  I assume it's not protruding.  

Saron81
Saron81 HalfDork
7/21/20 11:18 a.m.

A machine shop can most likely either remove the broken part properly and/ or heli coil a new hole for you for less than a new (used) head would cost.

TurnerX19
TurnerX19 SuperDork
7/21/20 11:31 a.m.

If you can anchor the head to the drill press table firmly you should be able to re-center the oversize hole. I would probably do it with a short end mill rather than a drill bit. Then use a Keen-sert or Timesert brand repair insert. 

914Driver
914Driver MegaDork
7/21/20 12:45 p.m.

If you use a drill press or Bridgeport, don't drill it.  It will just walk and try to follow the old hole.  Use a 2 flute end mill to get started and create a flat spot then a good center drill to an E-Z Out.  If you know the bolt's minor diameter and depth, you could 2 flute it down to looking like a helicoil then just unwind it with pliers.

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