Ive got my engine mostly finished (timing chain, head gaskets, intake gaskets, etc) and I went ahead and took the liberty of somehow breaking the crank pulley bolt. It broke INSIDE the snout, so theres no chance of welding a nut on to get it out. My only options are to drill it out and retap, or weld the damper to the snout. Drilling would take forever judging by the size of the bolt and how deep it is. Ive pretty much decided to weld the damper, but I just wanted to get some feedback from anyone who has attempted this. The damper key is fine and the damper is seated completely. Im not overly concerned about the seal getting hot, as this crank is pretty thick, plus the thickness of the damper hub. Like I said I already put a chain on it, so I dont think that will ever have to be done again due to the motor having 160k on it.

 

The bolt should be fairly easy to drill if you have the clearance to fit a drill motor in the space between the radiator and the crank. See if any of your friends have a 90-degree drill motor (cordless or otherwise). Chances are that the remaining bolt is not all that stuck in there and will come out fairly easily once you've drilled it large enough for a 1/4"-3/8" Ez-out.

If you've got the radiator out already then you've got no excuse but to do it right.

 

x2 on drilling it, take a center punch and make a center point in the bolt and drill it out, they are usually only grade 5 bolts which are fairly easy to drill out, run the drill at a slower speed so you don't burn up the bit and you should be good to go

 

Hit it with some penetrating oil, let it soak and then drill and EZ out it.

 

ok, you guys win. I had a lazy moment there. Tunnel vision because its almost finished. Drill, baby, drill.