fostersice

iTrader: (1)

help needed guys


just been out to remove the head bolts from the cosworth engine i got for my mk2 escort build

got 8 out but have fund 2 the are rounded off

these are the star type

do have have to drill the heads off then once the head is off try and remove the studs

or is there a tool out there to remove them

HELP PLEASE

Toe Knee

iTrader: (2)

you can get stud extraction tools where by you drill a hole thru the middle then wind the bit in and it bites in then u use that to remove it but be aware if the bolts are seized in then potentially i have had them snap on me before and their a bitch to drill out after!! probably easier as you have said tbh cos then u can just get a good set of mole grips on it after and it should come out. By drilling the head off the bolt you've removed the tension on it so should make it easier!

The other idea would be to hammer the next size up spline socket but the headbolts are torqued in very tight so probably wouldnt work, have done it that way on normal spline/torq bolts before

wirralphil

Toe Knee you mean EASYOUTS

tighten the other bolts as with them pulling the head down more will be easier on the easyout's

jon@work

iTrader: (5)

find the closest drill bit you've got that will just fit inside the bolt head. Drill down a few mm, and then try your original star tool again

fostersice

iTrader: (1)

i have used easyouts before and never again it snapped in the bolt i was trying to remove and you cant drill them out so i was fxxked so never again

TurboShed

Heating a stuck bolt can break the "stuck" remember, might help.

TurboShed

Or weld a nut on to it.

fostersice

iTrader: (1)

cosworth head i get to the bolt very easy

just had i look if i drill its going to send metal bits into the head

lloydmotorsport

iTrader: (1)

try tightening the bolt,this may break the seal,or at least straighten out the splines.
if not, then drill the head off it,

Red16

Before taking drastic action like drilling the heads off the bolts try knocking a smaller socket onto the rounded bolt heads then remove them, this usually works.

Or try a set of Irwin Bolt Grip Removers

Barry_GTi

Be careful with stretch bolts, as someone else said tighten in the other bolts again.

I have drilled the head right off the stud in the past and when the stretch was removed from the bolt it just twisted out by fingers. BE VERY CAREFUL if doing this as when the head comes away from the stud it can fire off like a bullet due to the stretch in the bolt, I lost the head of a bolt completely once fuck knows where it went.

Dan1281

twat a slightly smaller socket over it, that normally works

fostersice

iTrader: (1)

cant get a socket down the hole

looks like i have to drill the Fxxkers then try and remove the studs

what a rayol pain in the arse still them money i saved doing it my self mean i can now spend it on having the head stripped as i have to make sure theres no metal bits in it

just need to keep my eyes open for a set of cams to go back it

first time working on a engine and i pick a cosworth lol

Neil S

iTrader: (1)

I wouldn't try an easyout, headbolts are TIGHT and I've broken them at far lower torques - you'll never get the fucker out if it shears off!

I'd try and tighten it first, as said. I also like Jon@work's idea of drilling slightly then retrying the socket.

Might be easier to get square onto the bolt to drill it with the engine out, less risk of damaging the head then

See if you can get some tape round the area inside the head to minimise swarf, I cleaned mine in a parts washer then flushed it out thoroughly with a hosepipe as I was paranoid about swarf from the skim

wirralphil

I was gonna suggest a hoover, the swarf will be minimal.

RichieST

iTrader: (2)

True. Easyouts are hard as fuck, if you snap one inside the bolt there is no way you'll drill it out!

SteveB

iTrader: (3)

In reality the ONLY way to do it is to drill the head of the bolt off remove the head and then get the stud out that is left behind...... Don't need to worry about the swarf as the HEAD IS COMING OFF so can be cleaned once removed.....

Some of the suggestions above are clearly made by people who don't have a clue about removal of a Cosworth cylinder head and don't realise the severe lack of room where the head of the head bolt sits!!!!


Good luck
Steve

tabetha

I recently had to do one on cozmeisters head, as same thing some numpty fucked up the splines.
Just stuff some paper towel around the bolt hole etc, you can always wash out any swarf afterwards.
On cozmeisters car it was a rear one right next to oil return, so I simply packed the return with paper towel, then drilled a small 5 - 6mm pilot hole about 3/4" deep in centre of bolt head, then worked up in 0.5mm steps going to the same 3/4" depth each time, when it had worn through the outer "ring" that remained of the bolt head it simply let go, pulled drill out with ring still on bit, then lifted head off.
Head bolt material if stretch bolts is VERY soft, due to it's inherrant elastic nature, just be careful when using the larger size bits if the are cobalt(as mine are) as they are seriously sharp and bet to drill at a angle as best you can to start with when you feel the splines grabbing the bits, then straighten up drill, took us about 30 mins but all was well.
If you do decide to use any easy outs etc pray they don't snap,(which is likely) as you really will have problems trying to drill this material without it slipping off into the softer surrounding material.
As I see it you already have a "guide" there in the bolt head so use it.
tabetha

swebber23

How about sticking the other stretch bolts back in and torquing them up, then trying to undo the rounded off ones first? Or are they completely rounded off?

Toe Knee

iTrader: (2)

not quite sure why people are suggesting to use a smaller socket, ermmm cossie head bolts are a milti spline head not a normal bolt type so wont do much good

As a few people have said mate if the heads coming off then the swarf can be cleaned out after, its best to give it a good freshen up anyway if you've got it off and deff worth checking if its warped or not, depending which bolts are stuck if they've been left in the head then its had un even pressure left on it if you havnt put the other ones back in!

Kestrel77

How has this Progressed ?
It clearly seems to refit the others and then try the dud un...
In OTHER situations where you can access the bolt head, i have found it
VERY HELPFUL to file down some/all the edges and then fit a
smaller socket/spanner HEAT with blowtorch and remove (for any1 reading)
Bu this is very limites access, and so drilling with the above Excellent guide
By Tabetha, is the Way Forward here...
Let us know how you get on...
Paul

PhilM

For fook sake, if you do use Easyouts - make sure you use the short SnapOn type ones that are on a 1/2" hex base for a socket/spanner - NOT the long ones you use a tap wrench for!

And make sure you have the correct size Easyout and drill (pref. Left hand twist) combination for the fastener you are extracting!

fostersice

iTrader: (1)

NO EASYOUTS

ive started to drill but want to get some new drill bits so i will let you know tomorrow


thanks guys

like i said this is my first build and to have this happen has shit the life out of me

tabetha

Use COBALT if you can afford them, if not just decent HSS like DORMER etc.
tabetha

fostersice

iTrader: (1)

Buying the right tool v paying someone else to do it???

Bit of a no brainer

Still got to pay to have it stripped cleaned and skimmed if it neededs it
then new arp head bolt kit lol

And try and fine I inlet cam bd10 or been told bd14