need professinal help..

[RocCitySlayer]

When i bought my gsx i drove it home and noticed it had a very bad boost leak and exhaust leaks in 3 areas. I took the turbo off and noticed that 3 of the 8 bolts were broke off inside. I have tried drilling the bolts out to re-tap the threads but i cant get it to work. I need advise on what drill bit would be sufficent and if anybody knows where to buy 11grade bolts that are slightly bigger then the oem bolts. I have a hx35 by the way. any help is appreciated, Links are welcome and so are pms. thanks, Shawn

 

[Diamond Star Werks]

Get a screw extractor kit for any that you haven't completely drilled out already. Take your drill bits and match up one to be just slightly smaller than the 1/8 screw extractor piece. You should be able to buy these kits at a parts store. Also buy a punch, spring loaded one if you can get one. Use it to make the center so your drill bit doesn't wander during drilling. Don't buy cheap bits either as they have always had very short lifespans with me and had to sharpen some new as they wouldn't even drill. If they aren't broken flat try to flatten them with a small grinder to assist in the drilling. using a screw extractor should usually save you from having to re-thread the holes.

 

[RocCitySlayer]

I tried an extracter, It snapped in the middle of the bolt when trying to get it out, And the extracter was hardend, And with the cheap drill bits, I found that out the hard way when one actually shatterd when i tried to drill them out. As of right now theres only 2 bolts that need to be removed. And all threads are completly shot, So i have to drill and tap them all. I just cant find out what kind of drill bits i should use and where i can buy bigger sized bolts that can withstand the heat of the turbo and manifold. By the way the broken bolts and leaks are at the turbo to manifold

 

[dexterholland04]

Why not just weld a nut onto the brokn bolt and then heat it up and extract it that way? Since I hate extracting broken bolts, if it doesn't look like it is going to be an easy one, I just take it to a machine shop and let them deal with it!

 

[Diamond Star Werks]

I actually had a problem with getting an exhaust leak from turbo to manifold. One of the bolts would actually vibrate out till it hit the heat shield and only thing that stopped it is after I wrecked my car and swapped the engine into my other gst I used the bolts off the engine I pulled out and so far so good. Also don't use soft metal gasket as I had on the first time and 25% of it got completely blown of when i got an exhaust leak the first time. Use a real metal gasket. Advance auto parts sells a turbo gasket kit for about 25 $ and comes with a double plate gasket. Also here is where you can get some OEM turbo manifold bolts.
DSM OEM Turbo Bolts and washers kit - Turbo Accessories - Turbo - DSM Performance Parts | DSMparts.com I'll see if I can find some for manifold to block.
Edit: I say using the other bolts due to the fact the ones used at first to hold my turbo were not OEM bolts
Edit: Here is the address for the manifold to head stud set.
http://www.dsmparts.com/customer/product.php?productid=625&cat=0&page=1
I am not sure of finding any slightly bigger yet but i find some I'll let you know.

 

[RocCitySlayer]

I actually had a problem with getting an exhaust leak from turbo to manifold. One of the bolts would actually vibrate out till it hit the heat shield and only thing that stopped it is after I wrecked my car and swapped the engine into my other gst I used the bolts off the engine I pulled out and so far so good. Also don't use soft metal gasket as I had on the first time and 25% of it got completely blown of when i got an exhaust leak the first time. Use a real metal gasket. Advance auto parts sells a turbo gasket kit for about 25 $ and comes with a double plate gasket. Also here is where you can get some OEM turbo manifold bolts.
DSM OEM Turbo Bolts and washers kit#-#Turbo Accessories#-#Turbo#-#DSM Performance Parts | DSMparts.com I'll see if I can find some for manifold to block.
Edit: I say using the other bolts due to the fact the ones used at first to hold my turbo were not OEM bolts
Edit: Here is the address for the manifold to head stud set.
DSM OEM Exhaust Manifold Stud Kit#-#DSM Exhaust Manifolds#-#Engine#-#DSM Performance Parts | DSMparts.com
I am not sure of finding any slightly bigger yet but i find some I'll let you know.

Ok thank you. I did buy the falpro gasket set, And my turbo is not oem and the bolt holes are no longer oem size...

Why not just weld a nut onto the brokn bolt and then heat it up and extract it that way? Since I hate extracting broken bolts, if it doesn't look like it is going to be an easy one, I just take it to a machine shop and let them deal with it!

Any idea how much a machine shop would charge for what i need done?

 

[dexterholland04]

I would say for 2 bolts, maybe 25-30 dollars. It all depends on how long it take them! I paid 40 dollars last time for 3-bolts because it took them 3-4 hours to do.

 

[RocCitySlayer]

I would say for 2 bolts, maybe 25-30 dollars. It all depends on how long it take them! I paid 40 dollars last time for 3-bolts because it took them 3-4 hours to do.

Thats not bad at all, I just have to find a shop out here in rochester that does this

 

[bryanwheat]

When you put it back together use stainless bolts and it won't happen again.

 

[92AWDHX40]

EXTREME PSI : Your #1 Source for In Stock Performance Parts

Here you go great price.

 

[pos4g63]

Drilling out steel requires a low speed high pressure approach. Dont forget to use alot of lube. Use a dremel to grind the broken bolt flat, use a center punch and then drill away. Use progressivly bigger bits until you get to a point where the threads start. At this point you can try to pry the letfover pieces loose, then retap the holes with the same size as original. If that doesnt work then I would suggest possibly a helicoil or the next size bigger bolt. Have fun