forge bpv...failed :-(

C

channah

Member
:
08' mazdaspeed 3 sunlight silver
so tonite i finally get my bpv. i got to install it and everything is fine with taking off the stock bpv. i go to screww in the forge, and one of the screws head snaps off!!! great, so i go to kragen and get a tap set or whatever they are to take the rest of the screw out. go home and have no i dead how to use. end of stripping the existing part of the screw that was hanging out. so i had to take the intercooler off and then the cold pipe so tomorrow hopefully i can find a shop to take it out. im scared that i messed up the threading on the cold pipe and have to buy a whole new one. so ya such an easy install proved to not be so easy for me! im pissed to say the least.

any ideads?
 
Why did you buy a tap set that you have no idea how to use? You need a bolt extractor kit or if enough of the screw is hanging out try and gently un screw it with a pair of pliers. Find out what the thread pitch on the bolt is and then retap the pipe and get another screw. You must have been really crankin that for the bolt to break!

I would recommend you take it to a professional at this point
 
Last edited:
If just the head of the bolt popped off your fine. Don't panic. These bolts are not heafty becasue they are made to be at about 12-14ft/lbs I would imagine by the looks of them and the O ring on the BPV.
Take off the BPV and the other bolt. Then grab some nice sharp needle nosed vise grip pliers. Grab ther remainder of the busted bolt and unscrew it slowly. If you start chewing up the bolt then cut off the remainder and grind it down flat to the BPV mounting flange surface. Then drill a small hole in the middle of the busted bolt and go get an easy out. It will come out then.
 
If you are not comfortable with using an extractor and you already have the cold pipe off, I would definitely recommend taking it to someone who knows what they are doing. I do not believe based on what I have read that you should be using a grinder anywhere near the BPV sealing surface.

Run, don't walk, to the nearest tool store and get a torque wrench!
-enganear
 
Take your time with it if you chose to tackle it yourself. If you find that you have to use the easy-outs, then make sure you center the hole you drill down the center of the broken bolt/screw as best as you can, otherwise you'll probably never be able to unscrew it if you're not rotating at the center axis. Maybe try gently tapping an indentation with a sharp pointed tool and hammer at the center of the bolt so that its easier to line up your drill bit if using a hand held drill.

I sheared one of the bolts off for the plastic panel on top of the intercooler. Didn't have any luck with the easy outs. Ended up rushing to get it done with a battery powered, hand-held drill that kept seizing up the drill bit, although I eventually drilled thru and re-tapped it. Since I was in a hurry, I kept rotating my drill to penetrate thru faster and ended up boogering up my hole diamter so that when I tapped it, only the bottom half of the threads catch. Works for now. Guess its just an excuse to upgrade the IC down the road! Anyways, Good Luck!
 
enganear said:
I do not believe based on what I have read that you should be using a grinder anywhere near the BPV sealing surface.
Click to expand...

The BPV has an O ring on it and doesn't seal near the bolts. But, this is a VERY good point and I have to side with enganear here. Take it to a shop.
 
ok after 2 1/2 hours we finally get the damn thing out! the machinist said it was the hardest bolt he's taken out in two years. the b olt pretty much welded itself into the aluminum casting. its finally on and runnin, and i love it! thank god
 
channah said:
ok after 2 1/2 hours we finally get the damn thing out! the machinist said it was the hardest bolt he's taken out in two years. the b olt pretty much welded itself into the aluminum casting. its finally on and runnin, and i love it! thank god
Click to expand...

Was it cross threaded?
-enganear
 
to tell u the truth i have no idea whta happened. he had to use a edm machine and they a drill and then a tap[ and finally it all came out. literally 2 1/2 hours
 
channah said:
to tell u the truth i have no idea whta happened. he had to use a edm machine and they a drill and then a tap[ and finally it all came out. literally 2 1/2 hours
Click to expand...

Did he have to re-tap your original threads?
-enganear
 
He didnt install it correctly. NEVER wrench hard on bolts that are going into alumn. Im sure you learned a valuable lesson this time around. Easy with the gorilla hands!
 
haha no he actually didnt have to retap it suprisingly. i was really lucky. ya i guess i underestimate my own strength haha
 
I had the same problem because I was in a hurry and ended up snapping my bolt at the top which was good, took a pair of pliers and started unscrewing it and was good to go.
 
i seriously love it. i feel a big difference. i feel like theres almost no turbo lag anymore. and i LOVE the sound
 
Got mine today and installed it in about 5 mins. Love the PING sound. Does
feel like it holds boost better between shifts. Don't have a gauge, doubt if it
does anything else, but I still really like it.
 
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