'51 water outlet--broken bolt...

[mercuryct]

The car: a '51 Merc I've had for 42 years. The problem--when starting to replace the thermostats, I managed to break off the head of the front bolt of the passenger side water outlet housing. Part of the bolt, perhaps a quarter inch, rises above the surface of the head; so far, lots of Liquid Wrench and vice grips have not done the trick. Any suggestions? I've done this job--simple but pretty advanced as far as my mechanical capabilities go--on another flathead, but that job went smoothly. Or does anyone know a mechanic you'd trust with a flathead in the area 60-100 miles north of New York City? Are the good ones all gone, even older than me?

Thanks very much
mercuryct

[19Fordy]

The old candle wax wax trick works pretty good. Or use a propane torch to heat up the broken bolt then let it cool down. Then heat it up again and let it cool down again. Then apply candle wax and carefully grip and loosen the broken bolt - nice and slow, back and forth.
\https://www.google.com/webhp?sourcei...broken%20bolts

[D. Jones]

My usual way to remove broken bolts from cast iron is to TIG weld a nut to the remains of the bolt, getting the bolt red hot, then let it cool and slowly wiggle it back and forth using either wax or one of the better penetrating oils. The heat helps break the bolt loose. Sometimes the nuts twist off and it takes welding several nuts on to get the remains of the bolt out. Most people don't have a TIG welder, but any good welding shop will.

[B-O-B]

I might add to D.Jones post to place a washer under the nut before welding it to the broken bolt

[mercuryct]

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Thanks, guys. I really appreciate your help.