EMERGENCY HELP PLEASE!!!

Ok now I have a problem. I'm at the end of what so far has been a pretty easy upgrade of an EFM520 that was in my house when I bought it 2 years ago. I don't think it was taken very good care of so I've been working this summer/fall to get things done right. I thought ending today with putting in a domestic hot water coil gasket. Well despite starting to WD40 over a week ago and being careful to work the nut back and forth the lower right bolt snapped off. I don't know maybe it was leaking for years before I bolt the place and started to rust it out? WTF do I do now?!?! Is it something that can be welded? Tapped? Fixed? I'm really praying this simple last afternoon project hasn't totally F'd my boiler.

Thanks in advance to your response to my frantic post. ~Jeremy

rocketjeremy wrote:Ok now I have a problem. I'm at the end of what so far has been a pretty easy upgrade of an EFM520 that was in my house when I bought it 2 years ago. I don't think it was taken very good care of so I've been working this summer/fall to get things done right. I thought ending today with putting in a domestic hot water coil gasket. Well despite starting to WD40 over a week ago and being careful to work the nut back and forth the lower right bolt snapped off. I don't know maybe it was leaking for years before I bolt the place and started to rust it out? WTF do I do now?!?! Is it something that can be welded? Tapped? Fixed? I'm really praying this simple last afternoon project hasn't totally F'd my boiler.

Thanks in advance to your response to my frantic post. ~Jeremy

Drill the broken stud out re tapping with a 1/2 by 20 replace with a 1/2 x 20 bolt screw it in from the inside out put your gasket on and tighten up the nuts your done

I would put a bolt in from the outside. If it starts turning, how would you hold it on the inside?

Maybe a permanent type locktite on the bolt if you go that route, but cars use the outside bolt option all the time, with non-hardening Permatex.

....and put some anti=seize on the threaded portion. Next time you get brave, find a torch and gently heat the nuts, quench them, and carefully remove them one by one.

This is where I bitch about the old design of AA and EFM concerning the hot water coils. Look at the new style and understand what hundreds of guys learned the hard way. NOW, all you have to do is break it off, cut it off or some other simple method to change a gasket, or replace the coil. You, however should be able to drill out the broken stud and replace as chris or coal berner suggested. I have done the inside out method with grade 8 bolts myself, muttering the whole time about what kind of idiot would design a wear item that requires service to be so difficult.

Good luck, and hopefully you won't have to donate too much 'skin' to the project.

Update.....thanks for responding to my panic!! I guess I overreacted a little but I was having a )#%*)@(% I just bought a new boiler moment there. Once I got my head on straight I got a mig welder and some extra hands over here and we welded on a new bolt. Got the coil back in with a new gasket, some new unions for a quick change next time and we're heating up as we speak! Ah the smell of some fresh burning rice coal! That should get me through the night. Thanks to everyone for the advice! Virtual beers for all!

I just luv a Happy Ending!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

rocketjeremy wrote:Update.....thanks for responding to my panic!! I guess I overreacted a little but I was having a )#%*)@(% I just bought a new boiler moment there. Once I got my head on straight I got a mig welder and some extra hands over here and we welded on a new bolt. Got the coil back in with a new gasket, some new unions for a quick change next time and we're heating up as we speak! Ah the smell of some fresh burning rice coal! That should get me through the night. Thanks to everyone for the advice! Virtual beers for all!

Great should of told you about the welding the bolt in place part sorry forgot
Glad you got her fixed not as bad as you thought

No worries coal berner....I was very happy with your quick response! We weren't sure if we could do as nice of a weld job as factory to get a good seal with the gasket. So your plan definitely gave me hope for a plan B!!