part of cto broke off in manifold

[scott f]

I was trying to remove the old cto and the brass threads broke off in manifold. Is there a heli coil big enough to fit in there? Seems like I don't need to tighten this down very snug once I clean up the threads. Also, how do I get a tap in that small area?

[Stuka]

can you get the brass part inside the manifold out using a big easy out? that way you dont have to re-thread?

[Elliott]

If you hunt around or ask a machinist you will be able to locate a tap that has a flat nose (can't remember what they call them) for exactly that kind of situation. Best to be sure it threads exactly right from the start though as they are a little trickier to engage correctly in the threads you do have.

[tgreese]

Bottoming tap.

[jeep_bags]

Might be an excuse to upgrade to an aluminum intake????

[andy d]

you should be able to drill out most of it with a slightly smaller drill. then uses a small screwdriver or punch to work the remaining matl into the center of the hole. tyhat way , youl save the existing therads and will just need a cto. coupla wks ago, i sheared a banjo bolt holdin the air tubes to the exhaust manifold. i drilled it out to 1/2" and used an old spark plug to chase the threads.