Well, the lesson learned is, "leave well enough alone," or perhaps, "quit while you're ahead," or maybe "don't be an idiot." All seem applicable. Anyway, I had the heads off via removing all of the exhaust manifold bolts from the heads, and it was a success. Then, I decided it would be easier to removed the manifolds so that I could mount them on the bench before dropping in the refreshed heads. This would also give me the advantage of more room to clean the deck of the block. Well, it probably took me 25-30 minutes, and probably only a cuss word or two to get the passenger side out- halfway there! Well, the other side didn't go that well, and the main probably that led to a no turning back scenario is that the manifold rotated a bit on the y-pipe as I was attempting to wrestle one of the bolts out, so it wasn't going to line up when reinstalling the driver's side head. I tried to pivot the entire manifold back into position by slipping a breaker bar into one of the ports and prying it back into position, but no, it was going to bend something before moving back into position. So, it seems that only option left was to cut the bolt and figure it out later. Also, bonus shot showing a little tool carnage, and a shot of how I had to cut the bolt mostly by hand. That's right, I worked that little sawz-all blade back in forth for a little while. Also, a photo of how the manifold was perfectly perched for a reinstall, before I went a head and made things a lot worse. Oh, and I think I ruined the dipstick tube.
So, now it would seem my options include:
1-somehow removing that bolt stud from the manifold. Not much purchase anymore, but I do have the advantage of easy heating and juicing. Might have to try the crayon option that 410Fortune mentioned. If I had a welder, I think this would be the best option, to weld a nut to the stud, but I don't. Might be able to do that at a friends house.
2-drill out the bolt and tap it out for a bigger bolt. Not sure if I have that big of a tap, but certainly could buy one.
3-find another exhaust manifold somewhere.
Any thoughts?
In other news, the heads are getting refurbed at the machine shop. The guy there recommended new valve guides and a handful of the pushrods and rockers weren't good, so he ordered all new there. He is also going to do new valve seats, so I think it's going to run a lot better. After all this though, I don't think the head gaskets were actually bad, but it did need the top end gone through, so I'm not going to call it a waste of time.
