Engine strip woes

[phattanglo]

So I've finally started stripping my engine and I find myself with a good supply of seized bolts, screws etc.
Most of them I've sorted and the cases split was a lot easier than I expected.
Unfortunately the exhaust bolt is seized in the casing to the point where I snapped the head off completely.
I am loath to risk damaging the casing by attacking the bolt with a hammer and drift.
Can anyone who's had the same experience advise what to do.

[ironsloth]

Try a punch with a torx groove to then try to screw it out. Then soak some diesel into it. If that doesn't work, then drill it out very carefully, then run a tap through it using the same thread. Do this while swearing loudly, with a cup of tea.

[phattanglo]

It's the threadless hole that goes through the swingarm.
I was contemplating drilling it out but I wondered if it might be better to get it pressed out.

[mijapxman]

phattanglo, I've had to drill loads of these out, either because the bolt wasn't greased from the factory or the owner's haven't greased the bolt when re/fitting the exhaust.Not the best of jobs to have to do but needs must😱.
Start with a smaller drill then work up,use 2or 3 drill sizes, the hardest part is drilling in the centre of the bolt, the whole way through, if using a hand drill!
Use plenty of lube on it too and it may tap out before you've drilled right though with the final size drill, if the bolt isn't seized it's whole length (unlikely tho!).
Good luck.
Mij☺

[phattanglo]

I admitted defeat after going off centre with my drilling, so a local engineering firm is doing it.
It's £20 I would rather have spent on shiny things but what can you do.
This is just to get me back on the road, when I've retired will be the time for a full restoration.
That would be tomorrow if it was up to me but I'm sure the next 7 years will fly by 😁

[pxguru]

The exhaust bolts that seize are the old style (non-plated version) and that being the case the engine mounts are likely old and knackered too. Before attacking it with the power tools, if it were mine I would take out the engine mounts and blow torch the casing round the bolt and hit it with a drift and big hammer. Not many opportunities for the big hammer but this is one.

[phattanglo]

It's hard to say, it's a 2012 catalyzed model and when I changed the exhaust last year I used a boat load of coppaslip so I have no idea what's going on there but the swing arm bushes look ok.

[mijapxman]

I've had to drill all types of bolts, plated and no-plated.

Very, very rarely have I had one out using heat and a drift but it has happened, when it doesn't work you can end up distorting (mangling) the bolt making it harder to get out.😉

They are positioned perfectly to catch all the road crap, hence it's very common.😞

All the best.
Mij☺

[pxguru]

I don't see why you need to make these non comments. They are just pointless. I would imagine people leave here more confused than when they arrived!

[mijapxman]

pxguru, what are you talking about?

What non comments?

My post was aimed at the inexperienced people who read these posts😱. 

Oh, and I'll leave whatever I want on here as long as it's within the rules!🙈🙉🙊.

It's not up to you, or your buddy.😵😱

If you've got any thing to say to me, big man , feel free to PM me.

Mij ✊

[mijapxman]

Phattanglo, apologies for getting the handbags out on your thread 😉.

If I'd known you had the bolt out a year ago and had covered it in coppaslip, I too would have said heat and a drift, but with a nut ( or a few nuts if possible, but leaving room for the bolt to move, even a little to get it started moving) to try and stop the the bolt from distorting.
Good luck with it.
Mij☺

[phattanglo]

Haha no bother. It's out now so first days off work and we're cooking with gas.

[pxguru]

Glad its out. The newer engines like yours with the newfangled plating shouldn't corrode like the older ones did and I was thinking this is a bit odd, then I remembered something I heard about Coppaslip before. If certain types of Coppaslip are used on Aluminium and it gets wet, there can be a chemical reaction that causes some kind of accelerated corrosion. Exactly what you wouldn't expect.
White Lithium grease is the answer for things that can get wet, although any regular grease is still better than none.

[phattanglo]

When I get a new crux should I steer clear of ebay or has anyone had good results?

[mijapxman]

Phattanglo, I get my daughter to buy me a load of eBay parts, I bought a genuine cruciform from there, for my 200 engine rebuild.
Others may recommend other makes of cruciform as being better quality, as ever it's about choice😉.
All the best.
Mij☺