[indymanjoe]

Originally Posted by nUcLeArEnVoY

Three broken exhaust manny bolts turned a two-day job (since I take my time) into a 2 month ordeal, because I absolutely REFUSED to pull the engine or cylinder head. I really pat myself on the back for pulling it off, but I was able to drill out DEAD-ON-BALLS-CENTER all three exhaust bolts and retap the threads in the cylinder head without a single helicoil insert on the driver side of a 400 in a late 70's second gen. All with the engine still in the car. The main secret to my success was a centering jig called Beydler's Manibolt Driller (look it up) that uses a nearby open bolt hole to secure down an adjustable jig that centers in on your target broken bolt so you can drill it out on center every time. Otherwise, a couple right-angle drills; a low profile angle-drill attachment with threaded shank bits with a 3" total working height similar to aircraft angle drills; a custom-made low profile tap wrench; constantly raising and lowering the engine off the mounts; blood, sweat, lots of tears... and I finally did it. Took a wire wheel to the exhaust manny surface to clean it up, put in a new factory style shim gasket, and a crapton of nickel antiseize on the new bolts. Exhaust leak fixed.

I really gotta give it to myself for that. I just didn't want to pull the engine.

my Frame off started out as a broken exhaust manifold bolt...LOL