Burning out a rusted bolt

[pfarber]

Snapped off a stud in the exhaust manifold flange. Tried heat but the stud was so far gone it simply twisted off. So I tried a new method that really only works with low carbon steel in cast iron. The trick is that you need about 1/8th to 1/4in of the stud proud of the cast iron in order for the heat to stay in the steel and get it to the point where the oxygen flow can ignite the carbon. I use propane for heating/cutting (acetylene is insanely expensive) that's why I set the flame the way I do in the video... trust me, I know what I am doing. Plus Yeager my shop foreman was there to make sure I didn't blow up

Just a wee bit of stud left

rs_DSCN0317.jpg (133.18 KiB) Viewed 6482 times

[html5video][mp4]http://www.g508.com/forumposts/html5_videos/torchoutabolt.mp4[/mp4][ogg]http://www.g508.com/forumposts/html5_videos/torchoutabolt.ogg[/ogg][/html5video]

[pfarber]

This is the result:

rs_DSCN0328.jpg (148.94 KiB) Viewed 6478 times

Chase out the threads (you need a tapered point tap) or drill out to the next size and use a bolt/retap the threads.

Easy peasy.

[pfarber]