Re: restoring a 1966 5hp johnson
Re: restoring a 1966 5hp johnson
The ones that snapped are the ones that whent into the water jacket. Well atleast the mounting bolt. Don't know about the other one.
MAchine shops that specialize in removing broken head bolts from car engines have a trick,
they use a stick welder,
it works especially good on rusted exhaust to cylinder head bolts.
Put the clamp on the block and touch the electrode end (no welding stick)to the bolt for a second, the arc will burn the corrosion between the 2 objects (bolt and head) because thats where the resistance is. Then you should be able to remove it by hand because it will be quite loose.
If the bolt snaps off flush or beneath the surface of the head they just apply welds to the bolt or stud and keep building it up until it is above the surface then grab it with pliers, the trick is to allow it cool between welds.
One guy says he's never come across a stud he can't get out with this method. Another trick is to install a nut to the threaded bolt if theres enough thread, put a spot weld to lock the nut to the bolt and use a wrench to remove the broken bolt, the heat from the welder , again, turns the corrosion into ash making it even easier to get the bolt out.
They say helicoils are better for trashed threads.
BTW, in a recent issue of maching magazine they tested all the solvents commonly used for bolt removal, PBlaster, WD40 etc.
The winner was none of those products.
A mix of acetone and tranny fluid beat all of the commercial solvents.
It won by a wide margin of torque.
I'm a (very) amateur machinst and try to learn their tricks.
