broken exhause studs

[Duff]

i broke 3 exhaust studs off flush with the engine head. how the hell do i get em out. i tryed easy out but the hole i drilled was off center and now farked. how do you guys get em out.

[ofr57]

my guess ... get a little bigger drill bit and drill it in the center and try the easy out again

or if that fails drill the whole thing out and tap and die the new hole

[PJ.zook]

I extract em all the time at work. Easiest way i found, is to get an old nut thats internal diameter is around the same as the bolt, then hold it flush against the block, over the busted stud. Then mig the nut to the stud, being careful not to weld onto the block, hasnt happened to me yet but i dont want to find out how much of a pain it is to fix.
Then you just undo the nut and hopefully the stud will come with. If the weld breaks, try again.

[raptorthumper]

Stop now. Don't even consider trying anything else.

The only guaranteed solution is to pull the head off, and get the studs milled out, by a machine shop.

If you are unlucky enough to break an eazy out off in there as well the only solution is to go to someone with an EDM (Electrical discharge machining for those not in the know.) I know of a guy Walter from precision, Tool and die in Canterbury Rd Kilsyth Melbourne and he fantastic.

The edm machine so neatly removes hardened tool steel that the existing thread is untouched. If it is damaged he will helicoil it out to 12mm.

Speaking from experience, dont' butcher it yourself.



Cheers
Grant.

[up2nogood]

Yep, don't mess with it yourself.

But find a good exhaust tech who can weld them out. I have removed hundreds with no failures or head removals, but it took a lot of practice to be good at it.

[pongo]

Yep, been there butchered many, No if i break a bolt, it goes stright to an engineering joint and gets removed properly, Costs less too, if they dont have to fix my stuffup as well.

cheers

[jav]

you can buy drill bits that are made to run backwards, great for broken studs, usally when the drill bits in it unwinds the stud.

[Shadow]

weld a nut too it.

[Tiny]

then replace ALL the studs

[bazooked]

if you have already tried drilling it off centre dont waste ur time with backward drills or larger ones u will only fark it more, like mentioned earlier get it spark erroded most of the time it can be done without removing the head depending on how much room u have. i used to do this to alot of vehicles, namely trucks.