As far as bad days go, this one is fairly well up there. I have managed to snap not one, not two, not even 5, but a depressing 10 bolts off while trying to get them out.
(hhmm, thats a new smiley since I was last around)
I won't go into why I felt the need to go on this rampage of bolt snapping brutality, perhaps my DIY mechanical mind had turned to mush after a year of no ribbing and dossing around in canada or maybe I was day dreaming of hot summer days and glassy flat seas while each bolt went crack under surprisingly little load
Anyway, the engine as many of you will know is a 70hp tohatsu 4-stroke (1996 if I remember correctly) and I was trying to take the plate off the side to gain access to the cooling ducts that feed the tell tail so I could unblock it all. Each bolt screws through the plate, a gasket, a spacer plate and then another gasket (as far as I can tell) before screwing into the block. Each bolts appears to have snapped at the point where the plate meets the first gasket so if I do get the plate off there should be a little stump of each bolt left.
The plate is still on because there are 4 bolts at the bottom that I have not yet touched. If I snap these off too then the plate will come off but I would need to strip the engine and take the block off to access the broken bolts with a drill. For this reason I have left these intact and am hoping to get all the other broken bits out, stick new bolts in and unblock the cooling clog by some other means.
Does anyone have any experience of snapping bolts off and how did they get the bits out? Over the next few days I'll be squirting everything with plusgas but I have a feeling it won't be enough. I really don't want to have to buy a new engine because of this, not that I could afford to anyway.
I think I've probably thought of every possible option but the knowledge on this forum never ceases to surprise me so thought I'd give it a go.
Thanks in advance