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Re: Oops!! Broken Exaust Stud
[Re: mopowers]
#1438174
05/18/13 12:35 AM
05/18/13 12:35 AM
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Joined: Nov 2003
Posts: 36,040
Lincoln Nebraska
RapidRobert
Circle Track
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Circle Track
Joined: Nov 2003
Posts: 36,040
Lincoln Nebraska
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Rent a 90 degree (right angle) drill attachment
live every 24 hour block of time like it's your last day on earth
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Re: Oops!! Broken Exaust Stud
[Re: RapidRobert]
#1438175
05/18/13 12:42 AM
05/18/13 12:42 AM
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Joined: Nov 2007
Posts: 21,822
Kirkland, Washington
Pacnorthcuda
Too Many Posts
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Too Many Posts
Joined: Nov 2007
Posts: 21,822
Kirkland, Washington
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Quote:
Rent a 90 degree (right angle) drill attachment
And start soaking that with PBS blaster, (candle wax would be better if you blast it with a propane torch.)
Then drill a small hole as concentric as possible.
Some of this isn't easy. Use good sharp cutting tools, and proceed carefully.
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Re: Oops!! Broken Exaust Stud
[Re: Pacnorthcuda]
#1438177
05/18/13 01:23 AM
05/18/13 01:23 AM
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Joined: Jan 2004
Posts: 27,347
Today? Who Knows?
1_WILD_RT
Management Trainee
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Management Trainee
Joined: Jan 2004
Posts: 27,347
Today? Who Knows?
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Bolt the manifold back on, use it to guide the drill & keep it straight.. If you have access to a lathe I like to make a drill guide bushing, take round stock slightly to large to fit the bolt hole in your manifold & bore a 1/8" hole through the center of it, then turn the outside to just fit the bolt hole... Now you have a guide that will center the drill & keep it straight....
BTW you bolt is borderline to deep in the head for the weld a nut trick...
"The Armies of our ancestors were lucky, in that they were not trailed by a second army of pencil pushers."
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Re: Oops!! Broken Exaust Stud
[Re: pittsburghracer]
#1438181
05/18/13 08:53 AM
05/18/13 08:53 AM
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Joined: May 2003
Posts: 15,487
Florida
scratchnfotraction
I Live Here
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I Live Here
Joined: May 2003
Posts: 15,487
Florida
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why have studs in those holes anyways? stock it would have a bolt with a stud on each end. those are a blind hole with water behind it so dont drill to deep. I have trashed more heads for broken bolts/studs by hand drilling them. but I have bad luck at everything I try to fix. good luck 
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Re: Oops!! Broken Exaust Stud
[Re: ek3]
#1438185
05/18/13 11:31 AM
05/18/13 11:31 AM
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Joined: Jun 2005
Posts: 2,489
Tracy, New Brunswick, Canada
magnumcharger
top fuel
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top fuel
Joined: Jun 2005
Posts: 2,489
Tracy, New Brunswick, Canada
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Quote:
use a heavy washer first, then a nut welded on to the washer...turn it out while it is still very hot .it is a little deep but I have done them deeper. weld it from the center out to put heat on the bolt filling the nut with "weld " will add heat to the broken stud making it easy to remove . ... I have also had to deal with broken drill bits , not fun....
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Re: Oops!! Broken Exaust Stud
[Re: mopowers]
#1438187
05/18/13 11:40 AM
05/18/13 11:40 AM
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Joined: Nov 2007
Posts: 21,822
Kirkland, Washington
Pacnorthcuda
Too Many Posts
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Too Many Posts
Joined: Nov 2007
Posts: 21,822
Kirkland, Washington
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Get it good and hot and melt a bit of candle wax on it. A birthday candle touched onto the.hot broken stud would be perfect. The wax will migrate into the threads.
I don't see how welding anything onto the stud is an option, given its depth, but I not a great welder so maybe it's just me.
Using a guide to ensure concentricity with a drill is a great idea. Then use an easy out, or left handed drill.
Worst case, if you [Edited by Moparts - Family Friendly Site - Keep it clean] up the threads, just install a timesert (threaded insert, like a heli coil but better). I did that on the very same problem years ago.
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Re: Oops!! Broken Exaust Stud
[Re: magnumcharger]
#1438189
05/18/13 11:58 AM
05/18/13 11:58 AM
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Joined: Nov 2007
Posts: 21,822
Kirkland, Washington
Pacnorthcuda
Too Many Posts
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Too Many Posts
Joined: Nov 2007
Posts: 21,822
Kirkland, Washington
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Quote:
Don't drill!!!!!!!!!!!!!!!!!!!
Put a washer over the area of the broken stud. Make sure the hole in the washer is centered over the broken stud. Using a MIG welder, weld in the hole directing your arc at the broken stud.
The stud can be broken off below the surface - it doesn't matter! After the washer is welded to the stud, weld a nut to the washer...the same way. Look at my pictures above!!!
Here's the proof that it works great!!
Won't the hole just fill with weld, and make a bigger problem? Or does the weld not stick to the iron???
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Re: Oops!! Broken Exaust Stud
[Re: Pacnorthcuda]
#1438190
05/18/13 12:05 PM
05/18/13 12:05 PM
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Joined: Feb 2005
Posts: 28,312
Cincinnati, Ohio
Challenger 1
Too Many Posts
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Too Many Posts
Joined: Feb 2005
Posts: 28,312
Cincinnati, Ohio
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Quote:
Quote:
Don't drill!!!!!!!!!!!!!!!!!!!
Put a washer over the area of the broken stud. Make sure the hole in the washer is centered over the broken stud. Using a MIG welder, weld in the hole directing your arc at the broken stud.
The stud can be broken off below the surface - it doesn't matter! After the washer is welded to the stud, weld a nut to the washer...the same way. Look at my pictures above!!!
Here's the proof that it works great!!
Won't the hole just fill with weld, and make a bigger problem? Or does the weld not stick to the iron???
Most weld fillers won't stick to cast iron. 
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.... TRY the welding but I have never heard of that working well. I say GRIND the exposed stud flush or with a slight cup ....center a drill(1/8" or so) and drill it out ...then progressively go larger to the largest size that a GOOD square EZ out will fit ... then back it out slowly.
