Newbie advice please - welder needed for single job

Slowcoach · 2026-01-13T13:14:37+0000

Is it worth getting an induction heater, less damage than other heat, welding nuts on etc, possibly melt the plastic but hey ho.

dobbslc · 2026-01-13T13:18:32+0000

Welcome to the forum.
I'm surprised those bolts won't budge but luckily you haven't snapped any off yet!
Have you tried this type of extractor?

IRWIN Bolt Grip Fastener Remover Base Set of 5 | Toolden https://share.google/NMNsbRgpMqxEDPPGA

Or this type?

Look at this product that I found on google.com https://share.google/p7HFH1olTt5w8QqmZ

The top ones are much better.
If I was doing this I'd first try a 12 volt impact driver with an adapter on it to fit the hex, rattle it backwards and forwards gently but do it with a stinking hot engine as that will hopefully expand the alloy head a bit to help.
Bosch GDR 12V-105 12V Impact Driver | Bosch Impact Drivers | ITS.co.uk https://share.google/UUHb6bGCpWaAtxssa

Misterg · 2026-01-13T13:23:21+0000

Jembo28 said:
If it helps, here's a picture I found online of the cover in question - clearly the bolts in this picture have just been replaced!!! The tough ones to get to are behind that orange rubber hose (which comes off easily of course), but the shiny metal piece below the cover is very difficult to remove and has a "male" tube coming up that the orange hose goes onto and this interferes with the access to bolt number 11.

I don't think there's a hope in hell that the plastic cover would survive anything being welded to those bolts.

And welcome, btw.

steveo3002 · 2026-01-13T13:24:53+0000

are they known to seize into the head ? ive got some 80s cars and they still come apart okay

GaryS65 · 2026-01-13T13:44:32+0000

That doesn't look as bad as I first thought but still gonna be awkward and you will need a new cover.

addjunkie · 2026-01-13T13:49:36+0000

Can you get in to tap ( hit hardwith out mullering the head or anything else) them in wards, sometimes help loosen siezed threads.

JOEPRO · 2026-01-13T13:49:56+0000

GaryS65 said:
Stairway to misery. Unless the bolts are M10 plus forget using MIG. Let alone gasless mig or stick.

You'll want a TIG, + gas + welding helmet.

How much has the professional quoted? If the cover is plastic chances are it will still need replacement

I do M6 and smaller all time time with mig or arc even with a TIG available no need.

M6 example with mig

JOEPRO · 2026-01-13T13:51:15+0000

Jembo28 said:
If it helps, here's a picture I found online of the cover in question - clearly the bolts in this picture have just been replaced!!! The tough ones to get to are behind that orange rubber hose (which comes off easily of course), but the shiny metal piece below the cover is very difficult to remove and has a "male" tube coming up that the orange hose goes onto and this interferes with the access to bolt number 11.

Can you not get a pair of QUALITY Irwin etc mole grips and get them started? Nice exposed cap bolts.

jo1010 · 2026-01-13T13:51:18+0000

Just to add...as above....this is NOT the job for a newbie welder. Maybe an induction heater....but you also have to reckon with what happens if the bolts shear (small bolts notorious for that) leaving bits stuck in the engine.....needing further extraction / drilling and tapping.....
Maybe that's why you've been quoted what seems like big money....

hotponyshoes · 2026-01-13T14:07:22+0000

Get some decent drill bits a fraction bigger than the bolt thread and drill the heads off.
Lift the cover off over the remaining 'studs' then blowtorch on the protruding bits then a stud extractor.

BrokenBiker · 2026-01-13T14:22:37+0000

Slowcoach said:
Is it worth getting an induction heater, less damage than other heat, welding nuts on etc, possibly melt the plastic but hey ho.

heat is heat...an induction heater is going to have the bolt heads glowing in seconds, but for it to have any reasonable chance of working you will need to let the heat soak into the threaded area...this will almost certainly melt the plastic...

if you just heat the head up, all its going to do is increase the chance of rounding them even worse, or snapping one off...

addjunkie · 2026-01-13T14:25:05+0000

BrokenBiker said:
heat is heat...an induction heater is going to have the bolt heads glowing in seconds, but for it to have any reasonable chance of working you will need to let the heat soak into the threaded area...this will almost certainly melt the plastic...

if you just heat the head up, all its going to do is increase the chance of rounding them even worse, or snapping one off...

You could also use liquid N2. Everything would shrink at different rates, then when it normalises might come loose, not melted plastic, but it might become brittle and crack

Jembo28 · 2026-01-13T14:54:38+0000

JOEPRO said:
Can you not get a pair of QUALITY Irwin etc mole grips and get them started? Nice exposed cap bolts.

Tried that too with some brand new grips.

Jembo28 · 2026-01-13T14:58:49+0000

hotponyshoes said:
Get some decent drill bits a fraction bigger than the bolt thread and drill the heads off.
Lift the cover off over the remaining 'studs' then blowtorch on the protruding bits then a stud extractor.

Thanks for the suggestion. I expect this is probably the best bet for success but also better for someone experienced with this sort of work, but I'll be honest I'm very wary of deliberately leaving myself with the task of getting 11 seized studs out without even the head to get purchase!

JOEPRO · 2026-01-13T14:59:37+0000

Jembo28 said:
Tried that too with some brand new grips.

Were they off brand?

You need Irwin grips. Or Milwakee grips are good. Trust me it makes a significant difference

Jembo28 · 2026-01-13T15:01:55+0000

JOEPRO said:
Were they off brand?

You need Irwin grips. Or Milwakee grips are good. Trust me it makes a significant difference

They were - maybe one more go with some decent quality ones then. I'll have to find a free weekend again as it involves taking lots of bits off just to get to these bolts!

addjunkie · 2026-01-13T15:09:06+0000

Jembo28 said:
They were - maybe one more go with some decent quality ones then. I'll have to find a free weekend again as it involves taking lots of bits off just to get to these bolts!

Trade it in, on something newish, with a warranty and have more free weekends!

George A2Y · 2026-01-13T15:38:01+0000

Jembo28 said:
If it helps, here's a picture I found online of the cover in question - clearly the bolts in this picture have just been replaced!!! The tough ones to get to are behind that orange rubber hose (which comes off easily of course), but the shiny metal piece below the cover is very difficult to remove and has a "male" tube coming up that the orange hose goes onto and this interferes with the access to bolt number 11.

If you can drop pipes etc away to get better access maybe you could use a small rotabroach cutters in a drill ( match the inside of the cutter to either the stub or the flange of the fastener) the fastener would then guide the cutter. Cut down until you just touch the aluminium, the cover should then lift off. Any of the heat options can then be used to remove the fasteners. The cover could be re- attached using 6mm set screws and stainless penny washers.

Jembo28 · 2026-01-13T15:45:17+0000

George A2Y said:
If you can drop pipes etc away to get better access maybe you could use a small rotabroach cutters in a drill ( match the inside of the cutter to either the stub or the flange of the fastener) the fastener would then guide the cutter. Cut down until you just touch the aluminium, the cover should then lift off. Any of the heat options can then be used to remove the fasteners. The cover could be re- attached using 6mm set screws and stainless penny washers.

Thanks George - I'm still a little anxious about leaving myself with 11 seized studs to remove without heads for purchase. And I have 11 new specific bolts ready to go.

Shedendman · 2026-01-13T16:04:31+0000

Just my 2 pennys worth
You doing this with the engine cold? Will it start? could try taking them out when its hot,no?
:dontknow:

Newbie advice please - welder needed for single job

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