Major setback today.  The installing bolt (Grade 8) I was using broke off inside the crank.  The break is beyond the tip of the crank - I can't even see the bolt.  This could be the tipping point for a rebuild or long block.  I guess I could try to get an extractor in there and get the bolt out, but I don't relish that chore and I think the crank's threads are toast anyway.  If I used too short of a bolt they wouldn't grab and then with the longer bolt I was using I'm assuming it bottomed out too soon and broke as soon as I put some torque on it.  

Man o man o man o man o man! That's terrible ..I'm not going to think about what went wrong but how to fix this..there is two ways...a grade 8 bolt is hard so buy a bunch of good drill bits find dead center and work your way out..I would suggest a Mac set..high speed and warranty for breakage..and tap out the last bit of bolt..hope you get that far..not easy..forget the extractor..if you break off one of those in there you are done. The other is to replace the crank. This stinks..I got more I just can't think straight right now! This really got me peod! I hate this kinda crap! This really stinks.....
Richyostusota2011-02-13 23:30:28

Holy Moly!
Problem is gonna be IF that bolt bottomed out in the crank, then twisted off....it's gonna be next to impossible to ease-out it back out. It's gonna be in there under pressure. Drilling it on center is also gonna be tough, but it would certainly be worth a shot, rather than giving up on it. Drill it out starting with a smaller size, such as 1/4" to start with, then move up as you go, until you get to around 7/16" or so. Then spray some WD40(or whatever you use) down thru the hole and fill up the space. Let that sit for a day, or at least overnight. Then get the best ease-out you can get, and try it. If it doesn't feel like it's gonna budge at all, then it's time to start thinking about a new crank...or engine, if that's the way you're leaning.
I have had several of those bolts break off in the cranks. Some were never to be seen again, but quite a few I got out. A couple even spun farther in while drilling.
It's worth a shot.

btw...If you do get the twisted bolt out, PLEASE buy or borrow the install tool for the balancer...it will certainly make the day go much easier. Most parts houses have one they will rent out, or you could buy one and rent it out to your friends, or sell it on flea-bay(or here, even).
Adams' Apple2011-02-14 06:04:45

Thanks for the advice and condolences.  Still kind of in shock.  I'm a little freaked out about trying this, but I may still give it a shot -- not much to lose at this point.  Joel, I was a little confused by your drill bit sizes.  I think the bolt is only a 5/16" shank so I figured I'd start around 1/8" and work up to 1/4" or close.  A guy at work suggested a reverse drill bit - is that a possibility?  

A 5/16" crank bolt....on a small block? That might be the problem right there!
Just foolin...
Really, tho...5/16" is smaller than the valve cover bolts...the crank bolt is gonna be a 5/8" bolt, I think...maybe a 3/4". 

The reverse drill/bit might help, but IF the bolt has really bottomed on the crank, it prolly won't make any difference which direction the drill spins...the bolts is still gonna be bound up somewhat. It's definitely worth a shot....you're gonna have to drill a hole in it anyway.
Adams' Apple2011-02-15 06:22:33

You must be talking head size - I meant the shank.  It does use a 5/8" socket, but the shank measures 7/16" (I was 1/8" off in my estimation).  I think I'll try the reverse drill/bit plan first to see what happens.  Probably start around 3/16" or 1/4" and work my way out.   

Good luck on the reverse drill bit..I got a brand new set I haven't used yet if you need some.
Rich

Who says size doesn't matter?

Yer right tho...a 5/8" socket is usually a 7/16" bolt size. For some reason, I'm thinking the crank bolt is larger that that....shows how long it's been since I did any engine werk!
Whatever...Good Luck with it, and I sure hope it comes out!

We'll see, I'm hoping, too.  Not sure I'll try this weekend or not.  Might need a longer break from the thing than that.  Rich -- thanks for the offer, not sure you want me ruining or nice new set of bits, though!

They are snap on warranty for life..I breakem just to piss of the guy I bought them from..got to get your money out of them somehow!
Rich