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Old 10-28-2014, 05:06 PM   #1
Stre7ch OP
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Pissed Cracked bolt seat on the head, please tell me it's not as bad as it looks.

So there I was, doing an oil change, checking valves etc... And I go to put the left valve cover back on. Suddenly the bolt gave way. I took the cover back off to check and this is what I found:



What the hell do I do now? I put the cover back on with minimal torque on that bolt, then took it for a short ride, it doesn't seem to be leaking... But is it going to be ok? Should I leave it, maybe go to my buddies machine shop and see what we can do? Please don't say I need to get a new head.
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Stre7ch screwed with this post 10-28-2014 at 07:29 PM
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Old 10-28-2014, 05:18 PM   #2
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Don't freak. Very common. A helo coil is your best bet.
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Old 10-28-2014, 05:21 PM   #3
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relax,this is quite common.

It can be fixed. You will not need a new head.

I would use lots of spray cleaner, I use carb, then a little brake cleaner to degrease the area.

I would mix some JB weld, devcon titianum epoxy or the like and force it in the cracks, then gently force the cracks together, and let cure. Then I would add a layer of the same epoxy around the hole and let cure. Then I would add a helicoil.

This is a shoulder bolt, once the shoulder bottoms, quit tightening it.

Rod
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Old 10-28-2014, 05:26 PM   #4
JerryH
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Actually, you DO need a new head, unless a professional can fix it by welding. A makeshift repair as suggested MAY hold for awhile, but vibration will cause the cast aluminum to crack even more over time.
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Old 10-28-2014, 05:28 PM   #5
pistole
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I wouldn't use any adhesive there. Its exposed to both heat and oil.

and a helicoil isn't going to help since the bolt seat is cracked.

if the cracked piece came off , it would go into the engine....

so , perhaps ride it to a place which can weld aluminium and ask them for an opinion.
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Old 10-28-2014, 06:03 PM   #6
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Quote:
Originally Posted by Stre7ch View Post
So there I was, doing an oil change, checking valves etc... And I go to put the left valve cover back on. Suddenly the bolt gave way. I took the cover back off to check and this is what I found:



What the hell do I do now? I put the cover back on with minimal torque on that bolt, then took it for a short ride, it doesn't seem to be leaking... But is it going to be ok? Should I leave it, maybe go to my buddies machine shop and see what we can do? Please don't say I need to get a new head.
If the thread alone had pulled or stripped a helicoil would do, but the aluminum is cracked/split and if you helicoil it could fail. If it fails then you could end up with big chunks of aluminum in your engine.

Do you have any idea how much torque you applied? its possible there was a flaw in the metal but either way it needs welding or replacing. Not sure if they can weld that in-situ or if you have to pull the head to get it done?

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Old 10-28-2014, 06:17 PM   #7
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Weld, flatten (file to the same height as before. The OHC bolt bottoms applying the pressure to the gasket to seal the surfaces), drill, tap and be careful when you snug the OHC bolts henceforth.
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Old 10-28-2014, 06:31 PM   #8
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Just contacted my go to aluminum welder guy... He says it's a no go, and he doesn't know anyone who could do it... I wish it were as simple as JB weld, but I don't want to risk that coming undone. Looks like it's a new head for me.

Anybody have a link to where I can get one, or know somebody with a spare?
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Old 10-28-2014, 06:51 PM   #9
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Quote:
Originally Posted by def View Post
Weld, flatten (file to the same height as before. The OHC bolt bottoms applying the pressure to the gasket to seal the surfaces), drill, tap and be careful when you snug the OHC bolts henceforth.
This, and you do not need 40Nm of pressure on the bolt! It is only 8Nm, barely snug by a light tug.
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Old 10-28-2014, 06:52 PM   #10
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Quote:
Originally Posted by Stre7ch View Post
Just contacted my go to aluminum welder guy... He says it's a no go, and he doesn't know anyone who could do it... I wish it were as simple as JB weld, but I don't want to risk that coming undone. Looks like it's a new head for me.

Anybody have a link to where I can get one, or know somebody with a spare?
I promise you it has been done before. Talk to a competent machinist.
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Old 10-28-2014, 07:00 PM   #11
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This happened to me. My son totaled his 2007 GSA and I rebuilt it with a salvage title. On the side that had the broken valve cover, one of the bolt holes was warped and cracked. It was epoxied and helo coiled. One year and 15k miles later all is still good.
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Old 10-28-2014, 07:06 PM   #12
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No worries really if it breaks off and falls into the sump.

there is a strainer in there,and it is typical to find all sorts of treasures in a sump.


if its not leaking now I wouldnt worry about it.

next time you remove the bolt,maybe clean the hole and crack well.

fill with some sort of epoxy or JB weld.

put a stud in place of the bolt.

let it cure well, then that one corner of the valve cover an just wear an acorn nut.
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Old 10-28-2014, 07:13 PM   #13
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Originally Posted by JimVonBaden View Post
I promise you it has been done before. Talk to a competent machinist.
Well, my friend said it would have to be super heated, and that it'd ruin the integrity of the metal. It is cast aluminum right? Do you have any links to it being done?

Quote:
Originally Posted by Britome View Post
This happened to me. My son totaled his 2007 GSA and I rebuilt it with a salvage title. On the side that had the broken valve cover, one of the bolt holes was warped and cracked. It was epoxied and helo coiled. One year and 15k miles later all is still good.
Wouldn't happen to have a picture of how the epoxy has held up, would ya?
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And that he too, once had a doohickey modification...
All we know is he's not the Stig, he's some lunatic on two wheels."


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Old 10-28-2014, 07:23 PM   #14
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I'd mask the area off , clean it and reinforce with some epoy in the crack and around the broken part to try and keep the crack from spreading. Clamp it shut and let it set up. If the casting is deep enough, a long Timesert that reached down to the good material would take the stress off the broken section.

bemiiten screwed with this post 10-28-2014 at 07:31 PM
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Old 10-28-2014, 07:38 PM   #15
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Quote:
Originally Posted by Stre7ch View Post
Well, my friend said it would have to be super heated, and that it'd ruin the integrity of the metal. It is cast aluminum right? Do you have any links to it being done?
No offense to your friend, but he obviously does not know how to weld this. Take it to a machinist.

If you want to see how it is done do a search in the Garage section. This comes up often enough you should be able to find it.
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