Blaster Waveblaster 1 broken exhaust/manifold bolts..

[Quinc]

Bought a Waveblaster from a member here and he was kind enough to install a Coffman exhaust onto it before he sold it to me. After about 8 tanks of fuel it stopped running. Popped the hood and it was full of exhaust. Upon further inspection 4 bolts are missing! So it looks like the threads on the bottom one are jacked as the hole seems wider and ob longed shaped. Out of the two holes on the side of the manifold one has about 1/4 inch tell it hits a broken off bolt. The other one has about an inch or so before it comes to a stop, I am not sure if there is a broken bolt or not. Well out of the 4 bolt's that are missing I was only able to find 2 so I am thinking that the two had to much pressure/vibration and finally gave? Or is this something that's normal for wb1's?

So the question is how do I get them out, and how big I can re-tap the holes so I can fit larger bolts in? Also how do I keep it from happening again? The engine is a 61x.


3 bolt's that are missing:

Hole that is bit ob longed I am not sure if the bolt broke off or came loose?

Bad pic of the three holes:

The deeper manifold hole:

Broke off bolt about 1/4" in on manifold:

Exhaust side of missing bolts:

 

[TheBuzzard]

i am the coffmans expert. you are going to have to take the cylinder off. the cylinder hold down bolt that is snapped off should twist out with vice grips IF you can get the cylinder off. coffman exhausts create big power but are heavy cast turds that rattle apart if you dont keep up on them. those 4 bolts on that L bracket are supposed to and better be rubber mounted.probably arent and thats why s broke.

 

[Quinc]

i am the coffmans expert. you are going to have to take the cylinder off. the cylinder hold down bolt that is snapped off should twist out with vice grips IF you can get the cylinder off. coffman exhausts create big power but are heavy cast turds that rattle apart if you dont keep up on them. those 4 bolts on that L bracket are supposed to and better be rubber mounted.probably arent and thats why s broke.

The rubber is still there and I even tightened the top two on the pipe, didn't know the others existed tell I took off the pipe. Any tips or how to threads on taking the cylinder off?

 

[TheBuzzard]

that one thats snapped off is going to be the problem. the cyl has to slide up off that broken off bolt. any corrosion in there and it may not happen. thats usually when the BFH ( big in hammer) comes out and gets ruined.

 

[Quinc]

Any tips on how I can keep it from happening again? Can I add rubber to the mount points on the manifold and the front single bolt? Also any ideas where I can get the rubber?

 

[Quinc]

Good news:
Only 2 of the holes have broken bolts in them. I currently have them soaking in Kroil.
The cylinders have some really nice porting and polishing done
I found a Pro-tec sticker

Bad News:
2 of the holes have broken bolts in them!
The exhaust took me close to an hour to get off!
I found a very small hair line crack in the sleeve


Options:

Use a Dremel and or? and cut a notch in the top of the broken bolt so I can try a screw driver to get it out

Drive 1.5 hours north to the best Welder this side of the Mississippi and have him Heliarc it.

Or my least favorite option of using an easy out.


Broke bolt on the manifold

Some of the porting: