Removing Broken Bolt at the intake manifold

[jp_waltz]

I am putting things back together after replacing my HG and while torquing the bolts at the air intake chamber one of the bolts broke. The remaining bolt is in the threaded portion of the intake manifold so the broken part of the bolt sits recessed in the hole. I have a screw extractor kit but the bolt broke very unevenly and I cant get a hole in the middle of the bolt the get the extractor in. Does anyone have an alternate method the get this thing out without having to pull the thing apart again? I did some searching and didnt come up with anything that was close enough to this.
Thanks for the help,
Paul

 

[Joe_E]

I recently removed a frozen broken off bolt in an aluminum intake. I used a Dremel with a flat ended mill type bit to first even the end of the broken bolt so I could drill a hole in the center.

Being you broke it off putting it in it should hopefully come right out once you get a hole in it.
I on the other hand fought a vietnam with mine.

 

[jp_waltz]

I like the dremel idea. I will try that in the morning.
Thanks

 

[zuluzeugma]

Don't mean to be an ass, but you are center punching it before you try and drill right? A spring loaded center punch has always worked for me to get it started...

 

[brokenparts]

you could also use the dremel to cut a "slot" in the bolt and back it out with flat blade screwdriver. another choice is to weld another bolt to it and back it out.

 

[Pin_Head]

Welding could be dicey on an aluminum part; otherwise it is the way to go.

 

[ntsqd]

If it isn't too deep in the aluminum I use a nut centered over the remainder of the bolt. Then I weld it with a TIG thru the center of the nut while a wrench for the nut is sitting ready. I don't go for immediate extraction, I go back and forth wiggling it a little to get it loose and to feel if it now wants to come out.

If it is not happy I let it cool a bit and squirt PB Blaster on it, then try wiggling it some more. Once the PB has worked in a bit they usually come out.

 

[jp_waltz]

it is recessed in the hole. so there is no getting to it to weld anything to.

 

[ntsqd]

How deep?

I'm local if that helps any.

 

[jp_waltz]

its just into the threads of the intake manifold but about 3/4 of the way through the hole of the air intake chamber. Im not sure if that makes sense or not, anyway its recessed about 1/2 inch. I am on the east end of ventura and I will probably be in the driveway most of tomorrow trying to figure out if I have to pull the head off again or not. Any help would be greatly appreciated.
Thanks,
Paul