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snapped off exhaust stud

Discussion in 'Technical Q&A' started by ago car nut, Nov 25, 2012.

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  1. ago car nut

    ago car nut F1 Veteran
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    David A.
    #1 ago car nut, Nov 25, 2012
    A good idea for drilling out broken studs. Take a bolt that fits the header flange closely, Cut it off so it fits the header flange flush. Get your friendly machinist to drill a hole in the center of the bolt. Then put it in your header flange to center the hole you will drill in the broken stud. Once you get a hole centered in your broken stud you can increase the drill size, till you get to the tap drill size of the stud. What is left of the stud should peel out.



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  2. stevew3765

    stevew3765 Formula Junior

    Oct 27, 2012
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    #2 stevew3765, Nov 25, 2012
    Interesting. Did you anticipate that you might have an issue such as that when you started the project?
     
  3. ago car nut

    ago car nut F1 Veteran
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    #3 ago car nut, Nov 25, 2012
    No,

    I used it on other engine repairs. I thought it might help someone else.



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  4. stevew3765

    stevew3765 Formula Junior

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    #4 stevew3765, Nov 25, 2012
    Awesome. That's what the Brotherhood is all about! Thanks I will remember that when I am in a simular jam....The objest as I understand is to drill the bolt out until there is nothing left but a hoolw wall. Dissipate the metal...
     
  5. finnerty

    finnerty F1 World Champ

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    #5 finnerty, Nov 25, 2012
  6. stevew3765

    stevew3765 Formula Junior

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    #6 stevew3765, Nov 25, 2012
    hell, This is why I caruse this site so much. I always run across neat stuff. I saw ernies illustrated step by step cluctch replacent that looked so fun I alomost wanted my clutch to go out just so I could play. And now this....!!!
     
  7. 348Jeff

    348Jeff Formula 3

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    #7 348Jeff, Nov 26, 2012
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  8. Mark 328

    Mark 328 Formula Junior

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    #8 Mark 328, Nov 28, 2012
    What can work well is to smooth-out the top of the broken stud with a Dremel. If possible start a hole with either a Dremel or a drill bushing set-up.
    http://www.ebay.com/itm/5PCS-LOT-AA-BUSHING-CO-DRILL-JIG-BUSHINGS-1-2-9-32-5-32-5-16-40-/230888299429?pt=BI_Tool_Work_Holding&hash=item35c203dba5

    After a hole in the center of the stud is properly located a left-handed 1/8" drill bit can work well. When using a left-handed drill bit in many cases the broken fastener will spin right-out. You can then step-up the hole size with a bigger left handed drill bit.

    On a well rusted situation, after a 1/8" or larger hole is drilled heat the stud by putting the cone of an acetylene torch right in the hole and leave it there until the fastener gets red. The intense heat will stay with the fastener because the rust will insulate the heat in. No need to quench because the expansion will generally break any "bond".

    After the heating process an easy-out will usually spin a fastener-out.
    Another cold approach is to drill as much of the stud out; the more of the stud you get out the better; with only a little of the fastener left much of the pressure holding it will be relieved.
     

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