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Broke drill bit off in exhaust manifold bolt...

re>67 TR4a IRS
re> car has history of blowing out exhaust gasket 40k miles or so.

This vehicle has a total of 144k miles and had a major top and bottom rework at 80k.
Again it has had a history of exh manifold gasket blowouts every 35-40k miles.

The head and exh manifold were handed over to a machine shop for an alignment check.
Head manifold and block side were within 1.5mil of perfectly flat.

Manifold rear and front ports were 6 and 21 mil shorter (toward head) than the center ports (spec is < 4mil)
We are pretty sure this was the source of the exh manifold gasket blowouts.

Getting new (hardened) valve seats and should be as good as new in a week or so.
Valves were replaced 38k miles ago and still looked like new while the original seats were very recessed.
 
Glad it came out! I thought I'd just add that aluminum cutting fluid can be magical when it comes to freeing frozen bolts/studs. I've used it a number of times on my DD BMW E30 and on a couple stubborn pieces of the race cars and it works in minutes.
 
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