'84 Merc 150 - V6 2.0 - Frozen Bolt - Can't Get It Loose

[MAtkins]

Well, I've made a mess.

I had a head bolt that snapped off.
I got the other bolts out & got the head off.
About a 1/2" nub of the bolt was sticking out.
I grabbed it with a small pipe wrench.
I had great control and was very careful.
I sheared it off just about flush with the head.

I successfully drilled a bit about 3/4" into the bolt and snapped it off into the bolt.
Worse, I tried hitting it with a punch and snapped the tip of the punch off behind the bit.
I was obviously too tired to keep working.

I tried drilling it out again with 2 bits designed for hard steel.
I think the buried bit just cut the tips right off the other bits.

So, is there any way to get that bolt out now?

 

[wired247]

Re: '84 Merc 150 - V6 2.0 - Frozen Bolt - Can't Get It Loose

Stop what you are doing. Take it to a machine shop and have them lay it on a mill table and lock it down tight. A carbide 2 flute mill will cut right through all that crap. You might be able to clean the threads up but you may need to install a ( insert your favorite thread insert brand here ).

While you are at it have them deck the block. Florida motors all look like that.

 

[MAtkins]

Re: '84 Merc 150 - V6 2.0 - Frozen Bolt - Can't Get It Loose

Well, it's off to the machine shop.
They're gonna bore it and I'll talk to them about decking the block.
The guy indicated that they can probably get that bolt out without it costing too much.

We'll see what happens.
Thanks again Wired!