Rep Power: 369

so basically I finally realized being lazy and ignoring a problem will cause the problem to get worse...

here's the quick question. I stripped the threads for the aluminum block/exhaust manifold because I overtorque the upper right bolt for the header... (anyone know the thread specs for these bolts? heh)

I'm going to try to use a longer bolt, or reduce the gasket thickness, to hopefully catch some threads that are still okay deep in there...

but just incase none of those work... any suggestions on fixing the thread, if possible? or any remedies? like some kinda filling? heh. I wish I know more about the available tools out there.

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long version:

what happened was after swaping my stock header for an aftermarket one, I overtorqued (didn't have torque wrench then) the upper left bolt... and stripped some threads within the aluminum block (stupid move #1).... I got lucky though and it still tightens... so no gasket leak.

anyway I got a new header and the gasket that came with it was thicker, so the bolts couldn't catch any threads at all.. (obvious solution is to buy a bolt with same thread but longer so i can catch the deeper threads)

now I didn't get around to do that... and I drove the car for a few hundred miles without the header being tight (stupid move #2)

I didn't realize there's a problem till I'm experiencing, what I think is backfiring... basically the car is either running lean or rich, due to the spent gas going back into the engine via the manifold...

upon inspection, I think the gasket is totally burnt to a crisp. I'll found out tomorrow morning when I take off the header... I got a good feeling the gasket is blown fairly well though. hopefully I didn't damage the aluminum manifold head....

I'm gonna go back to the thinner stock Honda gasket, and try to find a bolt that match the threads... and hope that it will catch some thread and tighten the header to the manifold...

but incase it doesn't catch any threads, any ideas on repairing the stripped threads within the aluminum block? heh. is there any tools? like something that can fill it up? heh... sigh.

any suggestions will be greatly appreciated.

 
Rep Power: 369

um yeah I thought about it and I guess one of my option is using a thread insert...

but I haven't drilled and tapped stuff a lot... and I honestly dont want to screw up... hmm.

perhaps I'll take it to a shop if I'm desperate...

I duno if there's really any other method, but I'm still all ears if anyone have any suggestions.

hopefully the longer bolts will catch some threads.

 
Rep Power: 0

You could try a "thread cutter" (i think that's what it's called) The way it works is that it clamps on the end of the stripped stud, and you crank it on with a wrench. As it moves down the stud, it cuts new threads in the stud. As far as I know, most auto-shops have these, to solve the same problem you have. You might be able to rent one from a parts store.

 
Rep Power: 324

No what he needs is a tap not a die the threads inside the block are damaged not the threads on a stud.
Ok CapYoda You should have just thrown away the thick gasket that came with that header...but Going back to the honda one is a good move Try a longer bolt on the striped hole They are 8mm wide and the thread pitch is 1.25 disregard the size of the head. Get one that is 5mm longer than stock and try using it with the stock gasket. Tighten it last and to factory specs. 23ftlbs If it holds GREAT no prob. but if it lets go than take it to a shop and have them install a thread insert. Good Luck

 
Rep Power: 369

thanks for the info on the thread.

hopefully the longer bolt will work..

yeah I guess I'll have to take it to a shop if the longer bolt doesn't work... I can get the tools to drill and tap myself.. but I'm not confident about that.

 
Rep Power: 369

ah okay. got a longer bolt, and I'm using my previous stock gasket, temporary.

I got lucky too, cuz it just happened to be there, perfect length... it wasn't even in a package... (suppose to be two per package), its a flanged one too so it covers the area well...

so far it seems to be holding up well, I used a smaller torque wrench and I might not have torqued it to exact spec (around 20-24 lb.ft), since I can't find the adapter for my bigger adjustable torque wrench. (how come the tools are always misplaced when you need them, and you find them when you dont.)