Welding Explosion! Intense Bolt Extraction! Will it FAIL? Subaru Legacy Outback 2.2 2.5

[@RainmanRaysRepairs]

Back to the Broken Bolt Pt1 Mechanic Damages Engine! Drove IN Pushed Out! Subaru Outback Legacy 2.2 2.5 kzbin.info/www/bejne/fqecZn-Xbs2Zr7s

[@OSXMan]

I knew you'd get this after your last successful manifold bolt extraction on that Chevy pickup. You're getting better at welding. Soon you'll be getting it done in fewer and fewer tries.

[@Rekuzan]

You can always use a power strip for an I/O switch after bypassing the power switch.

[@woodchippers_WestWingDimeBag]

I would not have gotten it out while in the chassis because I would not have broken it off while in the chassis REEEEEEEEEEEEEEEEEEEEEEEEEEE

[@TOLDyouSOagain]

Good job Ray! I would elect putting a longer stud in that hole and using lock tite. That way the next water pump isn't an issue and that stud would never have to come out of those threads again, and it gives you the extra length

[@shadowur6305]

Off topic but the dashboard origin was very interesting. Have one to offer. With foot on the brake or hands on the steering wheel plus many other applications, what do you make of the word Haptic in your profession?

[@danmaynard1383]

Endeavor to persevere, Ray’s new motto. Who would have thought watching someone trying to extract a bolt would have me sitting on the edge of my seat at 4:30 in the morning. 😮😮

[@wineinbeautifulplaces1200]

We all do

[@haroldh3863]

It's the most authentic show on KZbin...and I feel every pain, every setback like it's my own because I have been there, done that, and suffered.. but hardly ever with the patients of Ray.

[@Wildman9]

Hahahahaha,me too.😂

[@MonkeyJedi99]

One thing I've learned from watching Ray for around two years is that my subjective distrust of bolt extractors is rational. I was trying to extricate a bolt from an excavator and went through seven bolt extractors before I gave up and played the game of gradually increasing drill bit sizes. Sure, I dinged the threads a little, but not enough to have to recoil the hole.

[@tonysolar284]

@@richpeggyfranks490 I found it kind of annoying. I prefer shop sounds over music overlay.

[@scottmarshall3963]

Bloody good job there, mate. You've done yourself proud. Perseverance is *definitely* the name of the game in these situations. Well done Ray - it's stuff like this that keeps us all coming back for more. No question that there's a whole chunk of the internet cheering and barracking for you and raising a glass to your success. Keep it up Ray, you're a true inspiration.

[@W4KG]

Hey Ray I'm a retired Robotics Engineer and Machinist. I always removed broken bolt's and stud's from equipment using the same procedure but after I welded the bead on the bolt I would chill it down and flood with penetrating oil. And tap with a small hammer to unlock the threads. Then weld the nut on and attempt extraction. Love watching the videos. Brings back a lot of knuckle busting memories.

[@nnglenn]

cooling and time is your friend!

[@michaelreischman9429]

And i always tighten it first, seems to break free better

[@MR-si1eq]

I'm not a welder but I thought it should cool down a lot more.

[@Stoney3K]

I suspect the slow cooling is what did the trick. The heat from the welding expanded the bolt which would wedge it in, and dousing the nut with penetrating oil doesn't really cool down the bolt enough for it to contract again. Cooling it down and then hitting it with some freeze spray might have made it even easier since the bolt would chill down and contract.

[@johnglasgow83]

I saw a video with a steel bolt in an aluminum block. They used a car battery after adding a bead to the bolt to heat up (red) the bolt. This caused expansion and contraction. One tip is not to quickly cool the welded area. This may cause the weld to crack. I like the tapping the bead with a hammer trick after cooling down. Patience and perseverance will always win.

[@chrissavage5966]

Another good save. Suggestion. Use the old waterpump as a guide, drill out that knackered thread and put an insert in place. Again, use the pump as a guide for the insert tap. It's a scrap pump anyway, so drilling out that one fixing hole to the correct size for each stage in that process is a zero-cost. I'd also suggest now might be a good time to go for gas shielding rather than that nasty gasless stuff.

[@johnnodge4327]

Install a m6 x 1mm stud to full depth of your threads, and use stud retainer locking compound. Then secure the pump with an m6 x 1mm nut. The stud with locking compound will allow more clamping force than trying to use a bolt.

[@duncancremin1708]

Now that’s a good idea. Why didn’t I think of that? It’ll still have different thermal movement characteristics, but it’s far less likely to pull out the remaining threads. That’s much better than my suggestion. Good one!

[@johnh8268]

Great idea!

[@cesardavrieux3767]

¡Exactamente!!! Sería lo mejor... he estado allí.

[@DCPHONEGUY]

that is a great idea that way you will get full penetration (ha ha)

[@INTHEWIND1833]

Helicoil with a stud, your golden. Strong work Ray.

[@billziegmond4943]

Persevere adapt and over come. I don't know who was more excited when it finally came out. You or I.

[@BULERICUSMAXIMUS]

Perseverance aka patient stubbornness will succeed almost every time. Well done Ray.

[@larrybe2900]

I agree but he needs to use more of his patiences up front before the original fastener breaks.

[@MaxVaughn-h9s]

You are more mentally tough than anyone I have ever met! Spending hours and hours on a seemingly hopeless extraction and coming out on top is amazing! Glad the other engine was not necessary.

[@Dis-Emboweled]

Yah need to make a trophy out of that bolt Ray! Just do a threaded insert Ray, they are actually stronger than the aluminum block. Great job!

[@paulmuff9883]

Exactly 👍👍

[@572Btriode]

I concur.

[@WhitentonMike]

Agreed. Also you are in a great location to install the threaded insert. Depending on how close you are to the water jacket, I'd put some JBWeld on the outside of the threaded insert to ensure the nutsert to block threads don't leak. I don't think the bolt itself will leak around the threads or it would have leaked from the factory. A very light amout of sealant on the bold threads can be added later if the bolt does seep under preassure.

[@ron1584]

The holes do not go all the way threw into the water jacket.

[@WhitentonMike]

@@ron1584 The reason I meantioned it was because he will need to drill out the hole to the size recommended by the nutsert and then tap it. I raised the point for others that might be dealing with a different engine and use the same extraction method that results in damaged threads.

[@brucecarrell4919]

Don't forget about the capacitor in side the unit. It holds a charge even when UN-pluged.

[@glennschemitsch8341]

YES......that would really hurt!

[@MacRODesign55]

I cannot believe how happy and relieved I am for you Ray. This is a fantastic result.

[@JasonBrown-edoc]

@RainmanRaysRepairs wanted to thank you. Our 04 f150 driver window fell down. Was able to pull the door card and get the window up temporarily. Couldn't have done it without your videos

[@cranefly23]

Nothing in the least sketchy to see here! 😂😂 Well done for having such patience, persistence and fortitude. I’m so pleased it’s working out for you. You deserve it. And thanks for giving me a few laughs at your expense!

[@brucegarrett7232]

You should have a collection of the broken/welded bolts to show the accomplishments you've done. And the equipment you've saved. Don't care about anybody else I like your terminology 😊

[@douguyehata7062]

Do they have EDM in your area ? At work ( aircraft engines ) they would remove steel bolts from aluminum cases/ light weight metal cases when they break in the holes. It would leave the threads undamage in the holes. Not sure how the processes works but it works well.

[@ronaldsinclair6837]

Ray I'll give you props for not giving up, hope the rest works out for you and the customer.

[@davepoxson8337]

I have been in this position, there not words to express how happy I am to se that broken bit of bolt come out, Congratulations!!

[@AdrianHeptinstall]

The cooling system is on fire! Excellent one sir 😎

[@dotar9586]

I hate when that happens.

[@JG-xo4ch]

Ray is consistently the calmest, most professional technician that I have ever seen. Many ratchet clickers and wrench turners should watch this and take notes. *breaks bolt off in block* “well that’s not what I wanted.”

[@richarddouchkov9453]

Sometimes you just need to improvise to get the job done. Well done Ray. So glad you saved that engine . You could have the hole aluminium welded and re-drill and thread. but a longer bolt to pick up the bottom threads is a good option. Awesome video. Kept be thoroughly engaged hoping for success. Ray is having himself a great day.

[@composedlight6850]

yep as you say aluminium weld and re tap i the best option --- or drill and use a threaded insert .

[@mikejacob3536]

That's a true souvenir! It needs to be preserved as a testimony to your perseverance!

[@richardsartor3140]

A little tip, if you are using Flux core weld, you don't need the shroud on the end of your mig gun, that is only for when you are using gas.

[@fostergaler8480]

If the threads aren't bottomed out in engine block, try tapping with a bottom tap to get more threads in bolt hole.

[@johndesaavedra1040]

Rainman, a thread chaser would apply here because they are less aggressive and can restore threads to the bottom. You can borrow them at parts stores. Loctite once made a product to restore threads with an epoxy compound to 80% of torque with all the threads stripped. Just sharing from experience.

[@goreng0033]

wow ray i seriously lost for a word..you patience is unbelievable

[@jeremyzammit3051]

Congratulations in finally beating the nemesis of all! usual rule of thumb if there is the left-over thread amount is as the bolt diameter that should be enough to hold otherwise changing that bolt to a stud which has been ground down to taper end to accommodate the no threads at base of hole will guaranty full grip!

[@forgetfulme1719]

he probably does not understand 'taper'=make ur own tap, in the softer aluminium.

[@michaeldelora5177]

Tool makers use bottoming taps after standard taps. The bottoming taps cut all the threads to the same depth. Then the stud adhered in the block as others in the comments suggested.

[@Shellcracker351]

I knew you could do it. As many times as you heated it and let it cool from welding, the easy-out was probably soft enough to drill by the time it finally came out. Now you need to glue that piece to a small nice of Mahogany, add an engraved brass plate giving the dates, and seal the whole thing with some extra clear table-top epoxy like they make the hatch cover tables out of. If your boy follows you in the biz, one day when he is facing the same thing, he can look over and see that Dad never gave up. Also, I know you know, but be sure to not use that welder much until you get the covers back on. That fan normally draws the cool air through the housing, and over the transformer and diodes. Without the cover on, the fan does nothing except circulate air around its self, and you can burn up a diode quick with a long weld.

[@larryscheuerman5396]

Congrats on getting that blasted bolt out Ray. All the trouble that bolt gave you I would hang it on the wall as a sign of victory lol. Again congrats on winning the battle.

[@williamsquires3070]

Yes, and make a note not to fight with Subaru engine water pumps anymore! 😅

[@OGYettie]

Congrats on the success, we'll earned. Probably the most exciting video in a long time.

[@johnkendrick7304]

My man, I cannot believe you persevered and got that stupid bolt out of there. Congratulations that was absolutely a job well done!

[@kingtut5923]

It's only a bolt not a valve in a heart , come on

[@JacobsDad]

You worked your magic on that job, Ray. It took some 'stick-to-it-iveness' and time but you did it. Saved the customer the cost of a new engine. You are gold.

[@davidhyde5536]

Well done Ray! Use a bottom tap to tap clear to the bottom of the hole and then use an appropriate stud and nut instead of a bolt.

[@Yawwee]

YES - THIS IS THE CORRECT REPAIR - JUST DO IT !!!!!!

[@Echristoffe]

Thanks for not giving up on this engine. Even if the thread are dead, I think an insert would be a valid solution.

[@Charlie_Crown]

Great demonstration of perseverance Ray, A+ 👌

[@brockett]

I was holding my breath so much I nearly passed out. Well done you for your perseverance. It's only insanity , as in doing the same thing over and over expecting a different result, if it never works, but it did work. So that's all right then.

[@glenndafoe8650]

The build up of anxiety in these stuck bolt removals is taking years off my life 😂

[@7700jessie]

You never gave up on it and that is what counts. Although to some people removing an engine just to extract 1 broken bolt may seem a tad bit extreme,...... but you had to do whatever it took to get the job done. CONGRATS!!

[@landontakeamericaback2106]

Yikes be careful I believe the welder has some large capacitors, discharge them always prior to Messing with it! And congrats on the bolt you stepped right in sit😂

[@chatrkat]

Patience and perseverance pays off! Proof right here as Ray performs another mechanical miracle. Nice work sir.

[@ws2664]

Good job skippy, just so you know a stripped out 6x1.00 hole is the perfect size for a 1/4 x 28 standard thread in case you already have the pump on and the bolt strips out you don't have to remove it, no drilling no heli coils just run the tap in and put the standard bolt in, we keep those bolts in stock at my shop, in different lengths, just for that.

[@NikHimself]

The cheering that I did as I leapt right out of my seat when that came out. I didn’t know how invested I was in this Rubisu engine. Well in Ray. Respect. Patience and perseverance.

[@Stoney3K]

Now this is why you hire a skilled mechanic who also knows his way around a workshop and knows how to do metalworking. You're an absolute craftsman, Ray.

[@TheLawnmowerLady]

I admire your tenacity! Perseverance pays in the end.

[@geordiegixxer]

Well done fella. That stud was an absolute stinker 😬 Your patience is unbounding 😂

[@drewv1785]

Wow! I was sweating just watching this! I think the bolt started to unthread at the 23 minute mark. You were still expecting the weld to break, but you were actually moving it. Cliffhanger!

[@lawllaygoh]

Woot! Good to see progress on that bolt extraction. After hearing the lost in transit engine, I was hoping to see you figure a way to get it done.

[@kwshilts]

A win is a win no matter how ugly. A testament to your skill.

[@douglasburnside]

Before you try and mount a water pump, take a straight edge and verify absolutely that the block is not warped or uneven after all that localized heat application. Resurface that area if necessary. Perhaps an extra-thick gasket could compensate for any unevenness.

[@BillFromAZ]

It's so awesome to hear the excitement in Ray's voice when he accomplishes something that he has lost hope in. I was so sure that last try had broken also, I almost fist pumped and shouted when I saw the bolt was out.

[@William_Hada]

Good job Ray! Patience and Persistence wins every time!

[@CMFL77]

Major second-hand anxiety! Had a similar battle with a water pump bolt on a Sonic 2 months ago. That was #3 for 2023 so now certain cars get a disclaimer to the customer before digging into one of those lol! I might have given up on the welding after the 20th break-off, good on you for sticking at it!

[@lisas3192]

You know you’ve got a good channel going when you’ve 38k views & 7k likes & counting as people get invested in watching you weld, weld, reweld, & weld again all hoping that you can work it out of there. Speaks to your originality, humor, & authenticity. Good show ol man.

[@Rickochetti]

This channel needs more broken bolts. It's very entertaining watching you save the world 😅👍

[@arnoldm889]

Congrats! I imagine the feeling of getting that out must be amazing!

[@keithvaughan6042]

I, myself did a short happy dance when thay bolt came out That was one of your toughest broke bolt removals Ray. Excellent. -SALUTE-

[@toolsinhand1911]

Major respect for keeping at it and not giving up. Virtual high five.

[@helenault7452]

Pulling the engine was the right move, straight from the get-go. Tiny extractors usually break off in my experience, so I almost never try to use them. But now you've got a half-damaged hole where you could do one more step and be back to having one as strong as it was before the bolt broke. Use the waterpump as a jig to counterbore the old threads out and shoot a Helicoil or Timesert in there.

[@kimkeam2094]

Glad to see the successful results but I must admit I would have immediately put in a helicoil.

[@kassemadam3005]

Thats what I was thinking. Is there a valid reason why some people dont even consider it until a last resort? Drilling and tapping a helicoil looks so much easier than this and itll introduce fresh threads. Any thoughts?

[@aperson9495]

A Time-Sert would be FAR superior.

[@dbutcher84]

The Subaru episodes had me on the edge of my seat more than any other of your videos. I didn't want to believe that one bolt could ruin the whole engine, so I was deeply satisfied when you got it👍

[@garynewell6947]

another epic video ray outstanding but the most important thing is to have yourself a great day ray

[@jimgraves4197]

That was always an engine out job, it's the kind of task that can lead to spanners bouncing off walls from sheer frustration. Well done Ray

[@johnstroup3191]

Was cheering so loud when that bolt came out my wife came inside asking what in the world happened. Lol. Woooo Hoooooo!!!! Great job!!!

[@tommyross2959]

I'm glad you didn't give up, very proud of you,

[@jgrenwod]

The bolt is stuck because of aluminum oxide from the steel and aluminum galvanic corrosion. Sulfuric and nitric acids can dissolve aluminum oxide, as can alkalis such as lye or caustic potash. Mixed with water, the alkali makes a caustic solution that dissolves the aluminum oxide.. that’s how it’s done..

[@danjordan1979]

You have no idea how satisfying that was seeing that bolt come out finally!!

[@dianab3827]

Who knew that so many people could be invested in removing a broken bolt. Excellent job!

[@robertbaird2005]

The results indicate your skill level. A few thoughts: plain unplated nuts just a bit better. Lightly tapping on the end of the assembly with a small hammer while turning back a forth seems to help. Final tapping with a bottoming tap, finally using a red lock tight stud in place of a bolt. Great videos feels like we're in the shop .

[@georgemalakasis]

Never give up. When you try hard, you win !!! Keep up the good work.

[@tihzho]

Glad to see you're not bursting into flames from the heat Ray!

[@rm-vh3mz]

You are absolutely great at our work.

[@joemuncie9187]

Nice save Ray. Even if you completely ruined the threads you could JB Weld a stud in the hole. I saved a 4 bolt main 350 Chevy block that way. An oil pan bolt hole was stripped and someone had tried to fix it VERY badly and drilled into the water jacket. I got the short block for free, JB Welded a stud in the hole and the engine lived for many years after I rebuilt it.

[@clintprice2123]

You were well rewarded for not giving up, well done Ray!

[@alanknoll5540]

That was awesome. You got that broken bolt removed. It lives again.

[@ImJustADave]

YO!! Congrats on the bolt extraction!! Saved that engine, and possibly the whole car, from the scrap heap!!

[@scottminer7702]

Congratulations, perfect example of "sometimes it works and sometimes it doesn't ".

[@christopherten-eyck4473]

I had this happen on replacement of a thermostat. Bolt snaped off. Used a drill and a snap on easy out to extract it. Worked 💪 Thanks for another great video. Hello from Pa USA 🇺🇸. Heat index 106.

[@gcrauwels941]

Glad you revisited that rather than completely give up on it.

[@AntonioClaudioMichael]

Nice work Ray Ya got it out. I would clean the Threads with a thread chaser 24:53 @Rainman Ray's Repairs

[@wonko3fc]

WHOOO0-HOOOO you got it out! Yaaaaayyyy Necessity is indeed, the mother of invention. TOP work Ray your patience and perseverance is inspirational.

[@wernerpd777]

A healthy dose of perseverance and patience along with never quitting will go a long way.

[@PaulHigginbothamSr]

You have renewed my faith in you after the replacement engine was lost. I can see this working with a bolt 1/4 inch longer. It has to be exactly the right length. Not short two threads and not bottoming before tight. I can see Ray drilling the hole two threads deeper but no more than that.

[@dmcmanis03]

I have a 11 caravan that the front crossmember/ radiator support bolt broke. I had to replace the entire front crossmember. Great that you finally got the bolt out.

[@shortbuss1979]

Your patience is amazing

[@jimwhalen6769]

Ray, I know you were successful this time but maybe a few tips for the next time. When using the brush to “clean” the weld area, you were actually introducing contaminates to the weld area and that is one of the reasons it kept breaking. Yes a tig welder works a lot better but a lot of guys do not have a tig welder. Ones you had the nut welded on and cooled a little, use the small propane torch to heat up the aluminum around the bolt! This process has worked very well for me in the past. I now have a tig welder and will use that on my next broken bolt!

[@leotuomi9767]

Success, patience and perseverance. So happy for you. You saved. the engine

[@invis7150]

I have read a lot of the comments and a lot of people were slamming your welding or your technique. That is all immaterial, the main thing is that bolt is out. To clean up threads to bottom is use a bottom tap or just grind your tap flat, you should get a couple more threads. I really enjoy your videos

[@bigkenny93]

Just a tip, take a small carbide burr on a die grinder and grind the end threads out of the hole before you weld. You can also shine the end of the broken bolt up with it also. Weld a washer, then weld a nut to the washer. I've done 100's over the years and that's the way. Lol

[@AntonioClaudioMichael]

Great video as always Ray have a great day @Rainman Ray's Repairs

[@ChazR25]

Such a satisying feeling once the stubborn bolt is out. Nice job detailing the sometimes frustrating process!

[@Dynasty1k]

Dude South Main Auto and Ray would make a hell of a mechanic duo. They’d be able to conquer anything auto related!

[@RainmanRaysRepairs]

💪

[@billboyer8897]

We always started with a left-handed drill-bit. Start with a small one, then work up to one just smaller than the tap drill size. In many cases, when you get close, the remains will unscrew themselves.

[@bignikaus]

This is a great outcome. You were already down the road of having to pull the engine so only time is consumed trying to save the block.

[@jorgefernandez-mv8hu]

Perseverance and Frankenwelder did the trick. Yeah!

[@Tedjenkins55]

bloody good job Ray, patience and perseverance wins the race that welded bolt deserves to be a desk orniment. Nothing is ever sketchey as long as you apply safety squints.

[@bradkline4023]

I'm glad you got this darned thing out since I had stopped breathing for extended periods of time getting close to passing out.

[@MrJet30]

Thanks for saving this 1999 vehicle. I also have a 1999 vehicle and i do everything i can to keep it on the road, I don't want any of these crazy newer vehicles.

[@chrissuessle]

Awesome, glad you got that apart and ready to go back together. I remember those days years ago of dealing with broken bolts and being afraid of it. But I’ve been a mechanic for over 30 years up in the rusty shit hole of New York State. Where broken bolts are just the way of life, the bolt you had broken there was amateur hour lol, I could’ve done it in the vehicle… but I have two drawers, dedicated to just broken bolt extraction in my KRL triple box. Over the years of having to deal with so many different, broken bolts, etc. I have gotten really good at getting things apart that mother nature no longer wanted to come apart. Maybe that’s what I should do is just make a KZbin channel of broken bolt extraction videos, because at my job, I do at least two or three broken bolts a week in various things, 99% success rate, but there are ones that have kicked my ass before. Mainly on rusty old Chrysler vehicles though. And, the older Japanese stuff, they made bolts out of clay. But I understand your frustration, it took me a long time to get as good as I am at it now, but that just comes with the territory.

[@danoakes8680]

Patience wins again. You have a good amount of experience with broken bolts. However your experience is still insufficient. You were winning with each back and forth turning of the nut. Where you lost was pushing the limits of each turn. The force was what you lost to. Had you be content with the back and forth only gain very little, it is the little that wins. Thanks Ray. The old school guy.

[@mustachemike802]

... "And now it's Miller time!"...😆Well played, sir... Well played...

[@poseyhollow]

Ray, I don't know about you, but I sure was happy to see you weren't gonna let that bolt kick your ass. Hopefully the block was able to withstand the heat, and all will be good. As meticulous as those folks are about the car, it will be like a family member coming home.