Welding a nut on to Cylinder head bolts

[Keithmac]

I come across this all the time at work (steel fasteners corroded into aluminium).

What you see on YouTube doesn't relate in any way to real life unfortunately.

I've been meaning to look into some core drill like cutters to go around 8mm studs, so you can cut the stud our of the head and still have enough meat for a Wurth Timesert repair.

You can't do it in your situation by my preferred method with exhaust removals is to cut the nuts off and try and salvage the studs, 9 times out of 10 that's a successful repair.

The problem is when the customer has had a go first and snapped 3 or 4 off flush with the head..

 

[Bobupndown]

….Id have run out of patience by now and started battering with a BFH!

This is the solution, not much a BFH can't resolve, judiciously applied violence

 

[Bullet2012]

A hydraulic hand pump could possible work, over the grease. Jet skis are almost as irritating as old outboards….Id have run out of patience by now and started battering with a BFH!

This is the solution, not much a BFH can't resolve, judiciously applied violence

After the burning , or before ?

 

[Markie93]

Right, guys I’m overwhelmed with the response. Thank you all for the great advice. As someone said earlier I had hoped the repair would not be such a big issue but I did buy it for a good price so I suppose that should have been a red flag. I can assure you all I would not buy another old jet ski!! . The thought of chopping it for parts goes through my head daily but I’m stubborn as an old goat at times and don’t want this to beat me.

The bolts are M10, 10mm shoulder and tapers in slightly but about 20-30mm until the thread, 70mm length overall.

I have tried to put the sparks back in and use the engine turning to pop it off but it won’t budge, it does have bad compression so that might explain that.

I have been soaking them in penetrating oil and as someone has mentioned and as per the manual I will try to weld a 20mm lock washer on to a spark plug that has had the head cut off to lift the cylinder head whilst using heat. If that doesn’t work I will need to lift the engine out. The reason I don’t want to lift the engine out as it is direct drive to the jet pump, so that will have to be removed also. However, the manual states to perform alignment again but you need a specific tool that costs $400 and I’m not paying that! I have a theory I can use my laser level, in the shipping industry we use lasers to align prop shafts only difference is we have datum points to go off. I will have to make my own datum points as I disassemble !

 

[ajlelectronics]

If that doesn’t work I will need to lift the engine out.

Hang the whole thing by its head off a crane for week, bashing the joint from time to time.