I was doing the egr removal for my 96 cummins 12v when I broke one of the bolts that holds the egr pipe on the exhaust manifold. Now I have a broken bolt on the manifold and a 1 inch hole where the egr pipe sat. Does anybody know how to fix this permanently with out taking the manifold out, drilling out that broke bolt and rethreading it. I am okay with that broken bolt because it broke off flush with the manifold. I just want to plug that 1 inch egr pipe hole permanently. Would I be able to weld a steel plate on the cast manifold or could I thread that 1 inch hole and run a short bolt down it? Pretty frustrated so any help would be great!

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if you have a welder, hold a nut to the broken bolt and weld up the inside of the nut and broken bolt. the heat will help break it loose and now you have a nut to help remove the broken piece

done this plenty of times, works great. sure beats drilling and tapping

 

We tried that and we broke the weld twice

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really?, interesting.

wire feed or stick? wire feed always seems to work best for this. for stubborn ones i have had to weld a small mound on the bolt first, then weld the nut on. the trick is to get it as hot as possible down at the bolt to make sure you are penetrating it well.

you can also try melting some wax on it while it is still hot and let it wick inside. when it cools down the wax will help lube it

if this doesn't work then i guess you are stuck with drilling it out or welding. i wouldn't weld the manifold though unless you could remove it and preheat it in an oven to about 400. other wise it is prone to cracking at the welds. use nickle rods if you do

 

It was wire feed but I will try again. That wax thing seems pretty smart I will try that

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