I have a '94 Z28 with broken exhaust bolts. On both sides, the two outer-most bolts broke off just below the surface of the head. After I removed the manifold, I noticed there's an "extra" hole located closer to the port. A search on this site showed ppl use this when they install headers.
I don't think I want to get headers. Instead, has anyone tried to drill the exhaust manifold to use the inner bolt holes? The bolt itself will clear the runner, but the bolt head won't. I'm thinking of welding a boss tall enough to clear the runner and using a long bolt. To make the boss, I would use a steel bushing, cut it to the length I need, and then cut it down the side so it sits flat against the runner.
Then, I'd just weld it all up and paint it black so it looks decent. Or, it might not need welding; It would just be a specialized, extra-long spacer. Think it could work??
Here's a diagram if it helps make more sense:
I don't think I want to get headers. Instead, has anyone tried to drill the exhaust manifold to use the inner bolt holes? The bolt itself will clear the runner, but the bolt head won't. I'm thinking of welding a boss tall enough to clear the runner and using a long bolt. To make the boss, I would use a steel bushing, cut it to the length I need, and then cut it down the side so it sits flat against the runner.
Then, I'd just weld it all up and paint it black so it looks decent. Or, it might not need welding; It would just be a specialized, extra-long spacer. Think it could work??
Here's a diagram if it helps make more sense:
![](http://ajb.dyndns.org/images/exhaust.jpg)
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