I had the same broken-bolt problem when I installed headers years ago. I
used a sharp 1/8” left-turning drill, which was part of an extraction kit,
and drilled all the way through the bolt. Going all the way through is
important. The center hole is open at the back, as I recall, so you can
also attack it with Kroil from the back side. Kroil also makes an
acceptable cutting fluid—also important. I enlarged the hole, and
eventually the left-turning bit pulled all the remains out.
I think the top bolt is needed to keep the manifold from rocking up and
down, but I may be the only one who thinks so.
As to the pitting, it depends on whether the pits create a tunnel around
the crush ridge on the copper gasket. You should be able to tell that by
inspection. If it might, then either plane it down more or use the Remflex
gasket. The carbon composite used by Remflex is a pretty good thermal
conductor. But copper is, of course, better. You can plane the manifold
with aluminum-oxide sandpaper laid down on a hard, flat surface, like a saw
table or even a smooth concrete floor.
Rick “whose manifolds were cracked, welded, and cracked again, making
headers an easy decision” Denney
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'73 X-Glacier 230 "Jaws"
Northern Virginia
Offlist email: rick at rickdenney dot com
Bruce,
Yes, there is a problem with Gr8 bolts in exhaust applications and there are actually two issues. Well three if you try to use them at Gr8 loads.
That last one is that as they are heat treated, they will actually unload (creep) at near normalization temperatures (~900°F). This is a time and
temperature problem that may take a while to show up.
The next problem is that the alloy of Gr8 fasteners is much more likely to cause transfer (aka gall) in a hot application. This is something you
really don't need.
A third issue is related to the first, but can get you even if they are not tensioned to Gr8 stress. As they are heat treated and with heat, they
will loose that temper, the frequently develop cracks at the thread root and so are prone to failure when any attempt to remove them is made.
I hope the Chemo does you well.
Hope to see you both at Mansfield.
Matt
--
Matt & Mary Colie - '73 Glacier 23 - Members GMCMI, GMCGL, GMCES
Electronically Controlled Quiet Engine Cooling Fan
OE Rear Drum Brakes with Applied Control Arms
SE Michigan - Twixt A2 and Detroit
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