Broken alternator bolt

[astat1]

Coming home from a show yesterday I noted my alt gauge heading south followed by a sound that sounded like something hitting my fan. The bolt holding the alternator into the head was hitting the fan. The remaining bolt needs to be removed. Its not quite flush with the head and a little uneven. I have never used an easy out bit before. I know this is torqued in pretty good. Any advise? Thanks

[srpntlair1]

depending on how much bolt is sticking out and access to a welder, spot weld another bolt to the broken stud, but be careful not to weld the stud in the head. if there is enough room, put a brass washer over  the stud

[astat1]

There isn't any shaft sticking out.

[GreenMachine]

   Yeah, that happened to me too. Mine was in an aluminum head and I just kept breaking easyouts. So I went to the junkyard and found a bracket (I think from a small block van). The bracket has jog on it that allows you to use a shorter bolt and nut. I think I had to grind on the bracket a little to work. You may even be able to find something laying around the garage. This will work until my heads come off sometime further down the road and I can have them fixed or just swap sides.
   Wow, looking at these pics, I didn't realize how dirty my engine is and that my valve covers are leaking.

[Steve P.]

You do NOT need to have any bolt hanging out of the head.. Remove the alt and make plenty room for mig welding. Use a 5/16ths hex nut. Hold it as centered as you can with needle nose pliers or needle nose vise grips and have a DAILY welder mig it up inside the nut.. Let it cool a bit and turn it out..

Make sure the new bolt DOES NOT bottom out in the head when tight..

Good luck....   


This is for after it is done...