exhaust leak.... broken bolts.... cracked manifold.

[mitsu_gst97]

so ive had my dsm for about 2 weeks now, ive been slowly correcting the past owner(s) many mistakes and i start investigating the exhaust leak i have somewhere around my manifold-turbo-downpipe. I remove the top heat shield to find a small crack in the manifold.

Better yet, one of the mani to turbo bolts, is just boucing around in the bolt hole. i pull it out to find a bolt with no threads.
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the turbo is going to be coming off this weekend. im hoping im able to get whats left of the bolt off with a stud remover, or even maybe the rigged way of welding the bolt back to the threads (if there is enough room, and ensuring nothing gets in the turbo)... If not, its off to the machine shop with my 16g. But hey this solves my boost creep problems


lucky for my car I enjoy working on it, im just strapped for cash and finals are in like a week and im freaking out about that shit.

 

[99gst_racer]

If there's enough of the broken bolt protruding from the flange, TIG weld a smaller bolt to it. Then use bees wax and rb it around the area of the broken bolt while it's still hot from welding. The bees wax will penetrate the threads alowing them to free up from their seized position. Then, unscrew the broken bolt out.

The reason for using a smaller bolt is that it's mucyh easier to weld a smaller bolt onto the broken bolt. This meathod has even worked for me when the broken bolt was broken off flush.

Ohh, and the FP cast manifold is still on sale, IIRC. No better time to pick one up to replace that cracked stocker.

Good luck.

 

[mitsu_gst97]

bees wax? like actual bees wax? Ooo sounds like i may not need a trip to the machine shop. would it be okay to mig weld instead of tig. Id like to try to get the bolt out without removing the turbo.