Exhaust manifold leak

[dagenham]

My exhaust manifold gasket is leaking, again. I know what the problem is but I need a couple of you guys to look at their engines for me.
The front top hole in the head for the manifold bolt is not stripped but the threads are not as deep as they once where and the bolt does not hold as well as it should and it tends to work loose. I dont think thread locker will do the trick.
Here is where I need your help.
I am worried that if I try to drill the hole out bigger to put a helicoil in it, it will weaken that ear and break off completely.
I am thinking about threading a longer bolt thru and putting a nut on it but there is a very thin casting web in the way. Can a couple of you guys look at your heads for me see if this is on your head also?? If it is not then I will simply grind it out of the way and put the nut on. I am just worried about making the ear to weak. This is a bone stock '66 200.

 

[MPGmustang]

I think if you grind it off only enough to get a nut on the back side you should be fine, you don't even need to hold the nut, let the extra casting do that for you.

you will have to strip out your current hole so that the bolt can pass through easily, if your thinking about upgrading this will hold you over for a long time, if not, I'm sure that just keeping an eye on it and snugging it every once in a while will make it hold better.

Good luck.

(I looked at mine and do have a 'web' on the front of the bolt hole of my 78 hex log. I would still try it, the worst you could do is break it and find a cheap $75 head at the junk yard)

 

[JackFish]

If it fails or breaks you may be able to get a stud welded on there.

 

[bubba22349]

You might also try a stud with larger size on one end (offset) instead of using a helicoil.

 

[292fan]

My flange also has the webbing.('63 170) I agree that if you remove just enough, you will be all right. Sometimes you can find a low profile or low clearance nut. I've seen some on a carb mount that were pretty thin in height and thickness.That would keep grinding to a minimum. If you want a pic of the flange, PM me.

Steve

 

[JHPSTANG]

The ear on mine broke trying to get out a stuck bolt. The machine shop welded in a stud and it has worked well. I hope you don't get to that point, but in case.
I'd try grinding down the web, or weld a stud into the hole you have if you are worried only about it backing out all the time.

 

[dagenham]

Thanks for the responses guys. The welding part is not a big deal, thats for sure. While reading everyones answers, I thought of something else maybe. What about a stud in the hole with JB Weld or something similar???

 

[chad]

find a cheap $75 head at the junk yard

OH, that I wish it were so. Not even available w/in thousand mi, I'd say.

Would you inform me if finding one (hex log - '77 +) that's usable? Everything round here goes to the crusher if 10 yrs old or older!!!