Exhaust Studs

[guest1406]

Hi all,

The worst has happened. Whilst changing the exhaust studs as they were bent, grotty and/or bald, one snapped. On closer inspection it shows that it has snapped out before it got to and awfully drilled out to a much larger diameter and bodged by somehow sticking a stud in there. First I welded a nut onto it and tried to get it out with a socket but it snapped with about 6 mm left of the bolt protruding. Then I cut a slot into it to get a flat head into it and use the impact drive to twist it out but no luck. Then I bought some easy outs and I thought it was working.. then the stud snapped about 8 mm in the stud hole.

I really don’t know what to do next. My one only thought would be to carefully drill out whats left of the entire steel stud and weld it all in with ali, drill a new hole in there and cut a new thread.

Any suggestions?
Thanks,

Mackenzie

[Steve Lake]

You've got it!.... plan D... clear the whole lot out and weld up, followed by drill & tap...  fit all new studs with a generous coating of copperslip.

think I've had to do this on at least 3 heads now...  the most awkward and frustrating bit is drilling out the old stud... you really need to get a pilot hole down the center of the old stud... or you'll find your drill bit will keep drifting off into the softer ally of the head, but you do need to get all the old stud out or it will interfere with both the weld up and the drill/tap...  I got an expert welder to do that bit... as the hole has to be pristine... or it'll end up with clag and gas holes and be bu55er all use to anyone.

good luck

[guest1406]

Ahh cheers Steve.

Plan B is never a nice thought. Plan D is just a kick in the groins. Especially when its the last part of the 17 month build!! Would be on the road if not for that. Well at least i know what has to be done. I cant ali weld but i know a few class welders about.

It wont be done for a while as uni work is pretty heavy but ill post how it all goes when it is done

Cheers,

Mackenzie