Heeeeeelp - Td5 Headbolt Broken - Need A Mobile Tig Welder

**Aukedrdw** · 6th November 2007, 05:22 PM

Guys I need someone's help BADLY.

Installing the head back into the Disco with all the new bits that I needed, I was 9/10th finished torqueing up the head ( did the 30 Nm, 65 Nm, 90 degrees, and was finishing the 180 degrees torque up) when - BAM - 2/3rds of one of the torque head bolt snapped off .......

Unfortunately, with MY luck, it wasn't one of the easy to get to FRONT bolts, no it had to be the B&%$#*D right at the back - nr11.

I have tried the following tools:

1) Chosel - No joy

2) Centre punch - No Joy

3) Air gun with smaller socket - SOME joy, the bolt moved 1/12th of a turn (anti-clockwise) and lost grip and stripped what was left of the structure on the head

4) Weld SOMETHING onto the head so that a socket / air gun can be put onto it - Now I have got a mig welder here (but no gas), but this tends to splutter & spark (even with the gas) and mates of mine in Europe used tig welders for these sofrts of jobs as they are much more precise, neat & tidy.

DOES ANYBODY HAVE A TIG WELDER & THE SKILL & THE TIME TO HELP ME OUT SOME EVENING THIS WEEK????

I am in the Epping area of Sydney and trays of beer are on offer.......for my 'hero'

Auke

**Blknight.aus** · 6th November 2007, 05:33 PM

mate you might get some joy with a right angle drill and bur r then an easy out if no-one can help with the mig bit.

if theres anything left poking out of the head you can also use one of those spiral drive sockets if you can knock one on enough to get a grip.

**Aukedrdw** · 6th November 2007, 06:32 PM

Guys,

Here are some pictures of my predicament.....

IMG_0087.jpg

IMG_0090.jpg

IMG_0091.jpg

IMG_0092.jpg

IMG_0093.jpg

The problem, if I didn't explain this correctly above, is that I can't undo the bolt any more to put another one in. I need to do this, as it is not up to full torque yet....

Hope someone can give me some guidance & a helping tig

Auke

**spudboy** · 6th November 2007, 06:34 PM

Have you got any bolt protruding at all?

Have you seen these sockets from Irwin:

http://www.irwin.com/irwin/consumer/...IrwinCat100511

I got a set from Gasweld for $49 for the base set. There is another add on set for $45 to complete the set.

HTH
David

**spudboy** · 6th November 2007, 06:36 PM

OK - you quick posted in between me typing and pressing send.

Now I can see what you are trying to sort out.

The biggest "head" in the set I mentioned above has a diameter of 18.3mm. Is that enough to go around the base of the stud?

**Bigbjorn** · 6th November 2007, 06:46 PM

Can you get a hand held battery drill in there? If so, go to an engineering supplier and get a HSS twist drill with left hand helix of appropriate size. File or grind a flat spot on top of the bolt, centre punch liberally, and use the left hand helix drill bit in the battery drill in reverse. The thrust of the cutting action will mostly unwind the broken bolt out of the head.

**Aukedrdw** · 6th November 2007, 06:50 PM

Spudboy,

Thanks, the bolt extractor sounds really good, but will this handle the torque (estimated 250 Nm +)?

The head is down to about 10mm.

**spudboy** · 6th November 2007, 06:54 PM

Well it's the same design as a normal Sidchrome type socket, and you drive it with a 27mm socket over the top of the extractor (well, 27mm for the 19mm extractor, 25mm for the 16mm extractor etc.).

250nm is a lot though.

**Blknight.aus** · 6th November 2007, 07:00 PM

Originally Posted by spudboy

Have you got any bolt protruding at all?

Have you seen these sockets from Irwin:

http://www.irwin.com/irwin/consumer/...IrwinCat100511

I got a set from Gasweld for $49 for the base set. There is another add on set for $45 to complete the set.

HTH
David

They are exactly the ones I was talking about, Go them first.

there is a shoulder on the bolt that you can CAREFULLY grind away to give it some fresh meat to bite into.

I'll be swinging past on saturday and will have a very slight amount of wiggle room in the schedule If you want me to have a look at it...

If you have no joy getting anyone else to voulenteer prior to thursday PM me and I'll throw my gasless Mig and air tools on board (Im assuming you have a decent air compressor)

Before you do ANY welding on it disconnect the battery, the alternator and the ECU.

mcrover · 6th November 2007, 07:03 PM

Drill out a 1/2" nut to fit snug over the left over head that is there and mig it to the top.

It should give enough purchase to get it un done.

You can just cover all the panels and the rest of the head with wet rags which will take care of the splatter.

To start with we dont know where you are as you dont have your location posted.

If you cant get gas then go get some gasless wire, small rolls are only about $20.

Failing that, just keep hammering smaller sockets onto it, not the best way to go but a bit of filing and a few sacraficial sockets normally does the trick.

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