A snapped bolt... oh no...

This is the place for your Cougar adventure stories. Do you drive your Classic Cougar? Tell us about it!
User avatar
ssava
Supporting Member
Supporting Member
Posts: 400
Joined: 22 Sep 2017, 13:13
Location: Franklin, TN
Contact:

A snapped bolt... oh no...

#1

Post by ssava » 05 Jan 2018, 15:02

So... my son and I decided to try and get the heater working. First thing we were told to do was to replace the thermostat.
A simple enough thing that we (amateurs) could do for only $5.99.

Unfortunately, it didn't work out that way.
One of the two bolts we had to take off to get to the thermostat SNAPPED.
IMG_3575.JPG
IMG_3575.JPG (148.12 KiB) Viewed 452 times
We tried everything. Reverse screw sets. Drilling. Bolt loosening sprays.
Nothing worked.

In desperation, we called a friend who had a friend who was a mechanic. He came over and tried for an hour to drill the bolt out.
No luck.

"You know", he said, "it's easier to replace the intake manifold.

Oh. Okay. Let's try that.

Now here's the thing. For Christmas... I got (or really Esmerelda got) new Valve covers.
IMG_3588.jpg
IMG_3588.jpg (165.05 KiB) Viewed 452 times
So we had fun putting those on the day after Christmas... and I guess we got comfortable working on her enough to try the thermostat.
Now we're in over our heads.

Fortunately we got the intake manifold in the next day and my buddy and his friend went to work (with my son and I watching and learning).
IMG_3589.jpg
IMG_3589.jpg (148.75 KiB) Viewed 452 times
We had to scrape off the old gasket and clean out the antifreeze
IMG_3590.jpg
IMG_3590.jpg (147.48 KiB) Viewed 452 times
Ready for the new gasket
IMG_3591.jpg
IMG_3591.jpg (167.79 KiB) Viewed 452 times
New gasket in
IMG_3592.jpg
IMG_3592.jpg (201.67 KiB) Viewed 452 times
We had to remove the distributor to get the new manifold in
IMG_3593.JPG
IMG_3593.JPG (171.69 KiB) Viewed 452 times
The bolts were then TOO short (2 inch) and we needed 2 1/4 inch bolts. But the auto store didn't have any. Nor did Home Depot.
So we bought 2 1/2 inch bolts and added washers for now.

Then... since we were putting in a new intake... we added a 4 barrel carburetor
IMG_3594.JPG
IMG_3594.JPG (191.78 KiB) Viewed 452 times


By now, it was 11pm and we were finding that the boxes did NOT include many things like couplers and throttle return springs.
So now she sits waiting for the last bits to come in.

I'm hoping by the end of the day we'll have her up and running again.

I'm told she'll have a few more horsepower when it's all done too.

Our $5.99 project suddenly became a $599 project overnight... ack.


And at the end of the day... my buddy looks at the old thermostat and says "This looks like it works just fine"

Sigh
"Esmerelda"
'67 Cougar XR7 purchased September, 2017 to work on with my twin (14) year old boys
Franklin, TN

cougarrand
Registered Member
Posts: 257
Joined: 09 Nov 2011, 05:05
Location: Beloit WI

Re: A snapped bolt... oh no...

#2

Post by cougarrand » 05 Jan 2018, 15:45

That's how it always starts!
Randy Feuillerat
67 XR7 GT 390 4V
68 390 X code XR7
68 XR7-G 302 2V
70 XR7 Convt 351 2V
70 Eliminator 351 4V 4 speed

User avatar
MrEos
Supporting Member
Supporting Member
Posts: 597
Joined: 24 Dec 2010, 22:42
Location: Duluth, Minn
Contact:

Re: A snapped bolt... oh no...

#3

Post by MrEos » 05 Jan 2018, 16:23

It's not a project unless you get a new tool out of the job....

DaveK
Registered Member
Posts: 160
Joined: 15 Jul 2013, 15:53
Location: Northern Virginia

Re: A snapped bolt... oh no...

#4

Post by DaveK » 05 Jan 2018, 18:06

Heat the manifold with a torch and you might be able to back that bolt out.

User avatar
Royce
Registered Member
Posts: 1182
Joined: 22 Oct 2011, 07:14
Location: Dallas, TX

Re: A snapped bolt... oh no...

#5

Post by Royce » 05 Jan 2018, 18:47

I've broken that bolt many times. I normally drill it out with a 1/8" drill followed by 7/32" followed by 1/4" then tap the hole 5/16" - 18.
1968 GT-E XR-7 W code 427 Augusta Green / Saddle
1968 XR-7 R code 428CJ Ram Air Red / Black
1910 Model T Ford Touring Red / Black
1914 Model T Touring Maroon / Black
1915 Model T Ford Touring Black / Black
1917 Model T Ford Torpedo Runabout Green / Black
XR7-G Registrar

User avatar
ssava
Supporting Member
Supporting Member
Posts: 400
Joined: 22 Sep 2017, 13:13
Location: Franklin, TN
Contact:

Re: A snapped bolt... oh no...

#6

Post by ssava » 05 Jan 2018, 19:16

Thanks all. I thought you'd share my misery/experience here.

As I've already got the new intake in... I've got the old one (with broken bolt still inside) off to the side in the garage.
I'm trying to keep all the original parts as we change them... just in case.
"Esmerelda"
'67 Cougar XR7 purchased September, 2017 to work on with my twin (14) year old boys
Franklin, TN

User avatar
CatsRock
Registered Member
Posts: 759
Joined: 17 Apr 2011, 07:32
Location: Ft Lauderdale Fl

Re: A snapped bolt... oh no...

#7

Post by CatsRock » 06 Jan 2018, 06:59

Been there done that too, luckily I was able to soak mine in pb blaster and use a reverse drill bit to back mine out. With that being said, although your project took a huge leap in price, the experience for you and your son can't have a price tag to it. And good move keeping the originals. Enjoy the ups and downs (at the end of the day lol ) cause now when you pop the hood you can say, yea we did that :smoke:
08 Suburban
1973 XR7 351Q Vert
EX 1975 Cougar XR7
EX 1972 Cougar XR7 Vert
EX 1967 Cougar

User avatar
JETEXAS
Registered Member
Posts: 376
Joined: 06 Aug 2017, 07:26
Location: Houston
Contact:

Re: A snapped bolt... oh no...

#8

Post by JETEXAS » 06 Jan 2018, 09:49

Now you need headers to complement the increased airflow from your new carb and manifold!
Image

User avatar
ssava
Supporting Member
Supporting Member
Posts: 400
Joined: 22 Sep 2017, 13:13
Location: Franklin, TN
Contact:

Re: A snapped bolt... oh no...

#9

Post by ssava » 06 Jan 2018, 15:08

JETEXAS wrote:
06 Jan 2018, 09:49
Now you need headers to complement the increased airflow from your new carb and manifold!
For real? Like will this be a problem?
Or would new headers be advised to compliment the new carburetor?
"Esmerelda"
'67 Cougar XR7 purchased September, 2017 to work on with my twin (14) year old boys
Franklin, TN

User avatar
ssava
Supporting Member
Supporting Member
Posts: 400
Joined: 22 Sep 2017, 13:13
Location: Franklin, TN
Contact:

Re: A snapped bolt... oh no...

#10

Post by ssava » 06 Jan 2018, 15:10

She’s done!
E9D4D490-FB3C-45F6-A077-EB5D29E00D65.jpeg
E9D4D490-FB3C-45F6-A077-EB5D29E00D65.jpeg (362.36 KiB) Viewed 356 times
"Esmerelda"
'67 Cougar XR7 purchased September, 2017 to work on with my twin (14) year old boys
Franklin, TN

Post Reply