The drill guide is a good option if there is room to get the drill in there.

Here is a picture of a home made drill guide in use. I had to drill out 48 1"x 6" bolts.

 

There is barely enough room for a drill. There may be enough room if I remove the radiator. Depends on how big the guide is. I'm going to have someone look at it.

 

I have a dewalt right angle drill you might check to see if something like that will give you enough room.

 

That's a pretty slick way of doing a drill guid but you would need a good bit of room for it I'll have to try and remember that one for my next nightmare.

 

The length of the guide was dictated by the length of the bolt I had to go through. I had to be sure the bit came through the center of the 6" bolt with no damage to the surrounding material.

 

I am delivering it to a guy today that can build a drill guide and hopefully drill it out. Just as a side note, when I bought the new Bolt from the dealership, the parts guy said that he had sold several of these bolts in the past 2 to 3 weeks. Must be a weak link. Beware if you are having to remove this bolt

 

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Just curious. What's the status?




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I have a guy working on it now. He felt confident that he could make a drill guide, drill it, put in a weld rod, then weld a head on it and back it out.(I believe that I said that right). Worse case he could thread the section of crank that is in front of the broken bolt and use a larger bolt.
He has had for a couple of days, just waiting to hear. I will let you know.

 

Well, i finally got my problem resolved. (hopefully!). I found a guy who was able to fix it. The old bolt couldnt be removed, but he was able to tap the end of the crank that was exposed and put a new larger diameter, but shorter bolt in it. He also replaced the crank seal and the harmonic balancer. So far, so good. No leaks!

 

That's great news! Been waiting to see the outcome of this.