Messed up real bad...any suggestions?

[lochenjons]

Throughout the 4 times I've taken the heads off my ironhead trying to get it to seal and fix all the other leaks, the bolt underneath the rocker panel (the "fun" one) got a little stripped so the last time I put back togethor I put it on the outside where it would be easy to get to so it wouldnt strip so bad that I would not be able to get it out. Well, being really stupid and frustated that it still leaked I torqued them down a little tighter (just under 80 ft/lbs).

Well, it still leaked so I ditched the copper gaskets and got some nice james head gaskets. Started to take everything apart (starting to get decently good at it too the 5th time around in 2 weeks) and came to that slightly stripped bolt. Trying to loosen it with the socket stripped it worse. Tried everything I could and finally got desperate and used the vise grips on it. All that managed to do was strip it worse and finally break the vise grips.

So do you guys got any tips to get this bolt out? If nothing works I'm gonna weld something onto it and loosen it that way...hopefully

[Highwayman]

Helli coils are your friend.

Either have them installed, or do them your self.

If you stripped them out, I suggest you have them done.

[mark_bert]

You stripped the head of the bolt, not the threads yes?

Try a small pipe wrench if you can fit it in there. If not, there are sockets made for getting off stripped heads. They have kind of a spiral inside that they lock to the stripped bolt head. Check at the Craftsman counter at Sears.

[lochenjons]

Originally Posted by mark_bert

You stripped the head of the bolt, not the threads yes?

Try a small pipe wrench if you can fit it in there. If not, there are sockets made for getting off stripped heads. They have kind of a spiral inside that they lock to the stripped bolt head. Check at the Craftsman counter at Sears.

Yes, the head of the bolt. We have those sockets at my work I'm gonna borrow them tonight. I have doubts they'll work with this tho

[Dr.Hess]

I'm not sure exactly which bolt you're talking about. Is it a 6 point bolt? Did you booger this with a 12 point socket? You tried the 6 point socket, right? Otherwise, try the special socket, or one of those sockets with all the wires inside that will grab anything if you can get it in there, or center punch it and drill a hole about the size of the thread minor diameter until the head pops off, or get the grinder out or Dremel brand moto tool and grind the head of the bolt off. Once it is all apart, you can get the rest of the bolt off with some vice grips, most likely.

Then, if your head gaskets are leaking, I'd be sure to have the jug and head surfaces checked for flat. Make sure nothing is sticking up, etc.

[lochenjons]

Originally Posted by Dr.Hess

I'm not sure exactly which bolt you're talking about. Is it a 6 point bolt? Did you booger this with a 12 point socket? You tried the 6 point socket, right? Otherwise, try the special socket, or one of those sockets with all the wires inside that will grab anything if you can get it in there, or center punch it and drill a hole about the size of the thread minor diameter until the head pops off, or get the grinder out or Dremel brand moto tool and grind the head of the bolt off. Once it is all apart, you can get the rest of the bolt off with some vice grips, most likely.

Then, if your head gaskets are leaking, I'd be sure to have the jug and head surfaces checked for flat. Make sure nothing is sticking up, etc.

Its the 12 point head gasket bolts

[Buddy Seat]

I would order a new set & replace them all.. They were originally 6 point bolts, IIRC ?

While waiting on the new ones, do as Dr.Hess has suggested..

If gasket surfaces need attention, no magic head gaskets are likely to fix your situation..

Then prep for assembly by wiping ALL the surfaces thoroughly with Brake-Kleen, or rubbing alcohol..(not for drinking) & leaves NO residue)

[lochenjons]

Got it out finally. Suprisingly to me I was able to get it out with the easy outs. The correct size was just barely too big so I had to hammer a smaller on there. After hammering for days I finally got it on there enough to take it out. Yes, I'm planning on replacing all of them.
Thanks guys

[motrhd]

Glad to see that you got the bolt out. Now you need to address your head gasket problem. Do you know that the cylinder and head surfaces are totally flat ? If they are then in to order to make the copper gaskets work I used a permatex product called Indian head shellac. The reason I had problems was the high compression with a narrow gasket. This was on an ironhead dragbike with over 300psi
cold cranking compression. It worked flawlessly, Good luck.