Broken Engine Cross Member Bolt

RagHead

Member
Sep 7, 2008
35
5
19
West Monroe, Louisiana
Looking for help or advice on the best way to remove a broken engine cross member bolt on my 66 mustang.
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2Blue2

will be trying this sex one when I can find it
Mar 5, 2019
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Drill it and easy out (which is never easy)
lots of heat, penetrating oil, and luck

Worse comes to worse drill bigger and weld coupling nut in almost flush and grind down flush.
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horse sence

That $5 hooker turn out to be a guy
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If you are good at welding ,weld through the hole in a nut like a plug weld to the broken bolt ,you would have to be careful to not weld the bolt in ,let it cool and soak with penetrating oil then turn it back and forth until it turns easily enough to turn it out
 
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RagHead

Member
Sep 7, 2008
35
5
19
West Monroe, Louisiana
Looking for help or advice on the best way to remove a broken engine cross member bolt on my 66 mustang.
rsz_3rsz_img_0052.jpg

Tried soaking this bolt with penetrating oil and using a left hand drill bit to try and remove it still would not come out and the bolt was broken to far into the frame rail to weld anything to it without welding it to the frame. After everything else failed I decided to cut a section of the outer frame rail out to try and remove it that way.
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After marking the section of the frame rail to be cut out and drilling pilot holes I made the final cut with a body saw and a 3 inch cut of wheel. This is how I ended the day, will work on getting the bolt out tomorrow.
 

RagHead

Member
Sep 7, 2008
35
5
19
West Monroe, Louisiana
Worked on the broken bolt today and after some heat and help from a air hammer/chisel finally got the nut and bolt out without damage to the frame rail so it's off the tractor supply for some replacement bolts.
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RagHead

Member
Sep 7, 2008
35
5
19
West Monroe, Louisiana
I went to tractor supply with the cross member bolt form the other side to get the correct size nut and bolt.
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Found some hardware that would work so it's back to work out the best way to fit everything, in the original mounting space by tacking the nut in the original space or tack the nut to a washer then the washer and nut over the original opening.
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Will try a test mount of the cross member later today to see which way is best.
 
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RagHead

Member
Sep 7, 2008
35
5
19
West Monroe, Louisiana
While waiting on the new cross member bolts to come in I test mounted the cross member with the bolt from the other side to determine the best way to attach the nut to the frame rail, with the nut on top of a washer or in the pocket. After trying to mount it with the nut on top of the washer and the nut in the pocket of the frame rail it appears that mounting it in the pocket is the best option.
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Now just waiting on the new bolts to come in
 

RagHead

Member
Sep 7, 2008
35
5
19
West Monroe, Louisiana
Well I got my engine cross member bolts in last week and mounted the cross member before welding the nut in to be sure everything was a good fit.
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After installing the cross member welded the nut to the frame rail
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Removed the bolt and put a good coat of never seize on it and reinstalled. It's not the prettiest weld but I torqued it to 50 ft lbs. several times before a final torque of 60 ft lbs with no problems or breaks. This is what it looks like after welding the plate back in.
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Now to clean up the rest of the frame rail a little touch up paint and all's done.