Thermoquad rebuild: Snapped butterfly screws:(
 

Evening folks. I wanted to see if anyone else had encountered busting the secondary butterfly screws out on a Thermoquad (TQ) rebuild. The odd thing is I prepped them the same as the primary butterfly and had no problem with removing those. I don't know if this happened because I didn't let the penetrating oil marinate long enough in them or if there was something wrong with the end of the screws or if it's because they were screws, as opposed to the 3/16" hex bolt.

I don't think there is any other way to get them out other than drilling them and tapping them. I don't think there is an E-Z out made this small;however, if there is, do let me know the PN# on it.

The only good news is I have another TQ here that had the butterflies bent up (don't ask me how, I bought it on Ebay for $10 just for parts) and am going to try filing down the outside of the bolts and letting the liquid wrench sit in longer this time; unless there are some other ideas or tips/tricks out there :)