removing exahust stud

[pishta]

outboard exhaust stud. Whats the trick? I got one out with jamb nut method, but I twisted the other right off. Tried to stick weld a nut on the stub but that twisted off too. Ended up drilling it out and tapping it, but my tap went in crooked so now I got a half azz 4 thread deep hole that im afraid to torque anything down in. Any tips, heat, cold, penetrating oil?? Stumped as I got 2 more to take out (the threads are jacked on all of them)

 

[67Dart273]

Make a jig or rig a manifold (junker?) to use as a drill guide. If you have a press, lathe, etc, drill a small grade 2 bolt to use as a bushing, IE saw off a bolt so it fits the top of the manifold, with maybe 1/4" or so of bolt shank to pilot into the manifold hole. Then carefully drill the bolt with maybe a 1/8 bit for a pilot.

Don't forget helicoils or other "thread inserts" to repair a screw-up

Another thing that can be handy is one of those "drill guides." I don't know if anyone still makes 'em. They were a deal that you hooked a drill to, had a second chuck on a shaft on sliding rails. A "shoe" on the bottom allowed you to hold the drill perpendicular to the work

This one is not exactly what I was talking about, but the same idea:

 

[Speedotann]

Some guy down the street from me uses a laser or something high tech like that.... my buddy had a stud break, while attempting to drill and retap, the hardened tip or the bit broke off and fused with the stud.... now it was impossible to drill out.... but this guy got it out! Wait, you live in TUSTIN??????? This guy is in Santa Ana!!

http://www.brokentap.com/

Good Luck,

Brian

 

[4woody]

Some guy down the street from me uses a laser or something high tech like that.... my buddy had a stud break, while attempting to drill and retap, the hardened tip or the bit broke off and fused with the stud.... now it was impossible to drill out.... but this guy got it out! Wait, you live in TUSTIN??????? This guy is in Santa Ana!!

http://www.brokentap.com/

Good Luck,

Brian

I'd never heard of that before. Nice to know there is such a service.

 

[daredevil]

laser aint cheap but its about the only way to remove a broken e/z out. easy out my ***. nothing easy about them.

 

[67Dart273]

laser aint cheap but its about the only way to remove a broken e/z out. easy out my ***. nothing easy about them.

Before we had lasers, a good man with a cutting torch could blow a steel stud out of a cast iron block.

 

[1wild&crazyguy]

tine sert.
I did all the exhaust threads this way just to avoid possible stripping of 40 yr old threads.



http://www.timesert.com/

 

[daredevil]

tine sert.
I did all the exhaust threads this way just to avoid possible stripping of 40 yr old threads.



http://www.timesert.com/

did you use standard size and smaller bolts or open your holes up?

 

[1wild&crazyguy]

opened the holes larger for the tine serts , used same 5/16 header bolts.

 

[1wild&crazyguy]

you have to counter sink just the right amount cause the sert has a lil flange, and I used red loc tite to hold'em
I used an old kwikway, but a good jig on a large drill press could work.

 

[RustyRatRod]

A mig welder is the ticket here. It gets WAY hotter than an arc welder and will heat the stud and head up when you weld the nut on and it will come right out. Tig welding also does the same thing, but lots of people don't have those.