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Info Dissolving Snapped Exhaust Header Bolts

Discussion in 'Tech Tips' started by Damus, Dec 22, 2016.

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  1. Damus

    Damus She is a BEAST and riding it is comparable to sex Dirty Wheel Club

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    Okay so due to @jazzhunt having loose header bolts I went and decided to tighten my own and ended up snapping 2 header bolts probably due to age/rust/whatever.
    I didn't think much of it a tried to drill a hole in the bolts and extract them using extractors but ended up snapping an extractor in the bolt and lets just say things got dire.
    My current situation looks allot like this:
    k.JPG

    Now using the wonders of science and this "ultimate header bolt obliteration kit" I have put together:
    IMG_1542.JPG

    I am going to dissolve the header bolts in the head.
    The idea here is I am going to use silicone to seal empty redbull cans over the bolts then add water and Potassium Aluminium Sulphate and have the steel bolts dissolve over a period of 24 hours. Note this will only work if you have an aluminium block otherwise the chemical will dissolve your engine along with the bolts. A quick way to determine this is to check if your block is magnetic using a magnet, if it is not magnetic odds are the block is aluminium.

    I will report back in 48 hours with pictures and results of the process.
     
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    Damus, Dec 22, 2016
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  2. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    if you've got access to a mig welder, put a tight fitting washer over the top and then weld the bolt end to the washer.
    Then weld a nut to the washer.
    Then ease it out slowly working backwards and forwards.

    The heating when welding will also aid in getting the thing loose.
     
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    ruckusman, Dec 22, 2016
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  3. Damus

    Damus She is a BEAST and riding it is comparable to sex Dirty Wheel Club

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    As fun as that sounds this is for science!!! And may you all be shocked and impressed by the brilliance of this approach.
     
    Damus, Dec 22, 2016
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  4. kiffsta

    kiffsta Senior Member

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    IMG_0927.JPG
     
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    kiffsta, Dec 22, 2016
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  5. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Yep it'll work, would happen a bit quicker if you add some heat and a bit of Peroxide to it

     
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    my67xr, Dec 22, 2016
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  6. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    [​IMG]
     
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    ruckusman, Dec 22, 2016
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  7. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    George-Costanza-Eating-Popcorn.gif
     
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    GreyImport, Dec 22, 2016
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  8. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    That guy is absolutely awesome - Damn reminds me of tool time, he could have his own show and I'd watch every episode
     
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    ruckusman, Dec 22, 2016
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  9. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Lol, yeah he's a funny Canadian
    @Damus If you have any Alum left over you can alway's make some pickle's...
     
    my67xr, Dec 22, 2016
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  10. Damus

    Damus She is a BEAST and riding it is comparable to sex Dirty Wheel Club

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    It actually wasn't easy to get my hands on to be honest. It has quite a high toxicity and Australia is putting a red cross on these types of things. I'm going to be as sparing as I can with it in case one day someone else or I run into a similar problem again.
     
    Damus, Dec 22, 2016
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  11. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    The Chemical mob up the road from me where i got the Nickel Sulphate sell's the Aluminium Potassium Sulphate (Potash Alum)
     
    my67xr, Dec 22, 2016
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  12. risky

    risky risky

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    have you thought of re- sharpenning a concrete drill. sounds unrealistic but works.
     
    risky, Dec 22, 2016
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  13. Spotthedogg

    Spotthedogg Active Member Premium Member

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    so your exhaust port is in your block eh?? :thumb_ups:
     
    Spotthedogg, Dec 23, 2016
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  14. Damus

    Damus She is a BEAST and riding it is comparable to sex Dirty Wheel Club

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    Hahaha smart a$$, the head then?, cam cover? rocker cover? Valve cover? What do people call it these days?
     
    Damus, Dec 23, 2016
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  15. Spotthedogg

    Spotthedogg Active Member Premium Member

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    well let's hope it's in the head :drinks:
     
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    Spotthedogg, Dec 23, 2016
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  16. Damus

    Damus She is a BEAST and riding it is comparable to sex Dirty Wheel Club

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    **Update**
    Okay... So, after taking off the headers I was inspecting my bike and realized I blew my reg/rec, THANKS FORSETI! You lying piece of Chinese ****! That's now the second Chinese electrical component to go in a month. Wires were damaged so off a temporary parts bike I have I clipped off the reg/rec and wires to solder on after this bolt nightmare is over. Also I took my battery up stairs for charging.

    Annnnyway to get this to work I ended up having to lay the bike on its side. I actually used some old hair colouring kit hydrogen peroxide to accelerate the reaction. See photos below.
    -Time 7:30am
    IMG_1544.JPG
     
    Damus, Dec 23, 2016
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  17. Damus

    Damus She is a BEAST and riding it is comparable to sex Dirty Wheel Club

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    image.jpg

    image.jpg

    image.jpg

    image.jpg

    And the waiting game begins, what's annoying is I have to do this twice...
     
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    Damus, Dec 23, 2016
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  18. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    That chain looks tight, or is it an optical illusion?
     
    maelstrom, Dec 23, 2016
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  19. Damus

    Damus She is a BEAST and riding it is comparable to sex Dirty Wheel Club

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    Does need a clean and lube, because of that there is tight spots but yeah my eye is on it.
     
    Damus, Dec 23, 2016
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  20. kiffsta

    kiffsta Senior Member

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    I tnink we need a status update
     
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    kiffsta, Dec 23, 2016
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