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Re: twisted off exhaust manifold studs on 440? [Re: mopar_man] #298389
04/25/09 08:55 PM
04/25/09 08:55 PM
Joined: Apr 2006
Posts: 334
hickory nc USA
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skyhawk61 Offline
enthusiast
skyhawk61  Offline
enthusiast
S

Joined: Apr 2006
Posts: 334
hickory nc USA
If you have more than one stud broken off, bite the bullet and remove the head. I've repaired one or two in the car, but removing the head is really the best way to fix it. Go ahead and replace ALL the studs with quality fasteners while it's off.
Back in the early 70's, I broke the last exhaust stud on cylinder #8 on a 383. Basically broke($) at the time, I removed the exhaust manifold, then welded a drill bit to a foot-long 1/4 rod; I used a hole saw to drill a 1" hole in the fender well directly across from the broken stud, drilled it out, ran a tap in it, and replaced the stud. Put a body plug in the fender hole, covered it with undercoat and I was back in business. Sold the car years later...ff you happen to have a red and black 68 Road Runner hardtop from NC with a funny hole in the passenger side fender well, now you know how it got there!!

Re: twisted off exhaust manifold studs on 440? [Re: 61 NYer Convt] #298390
04/25/09 09:18 PM
04/25/09 09:18 PM
Joined: Nov 2008
Posts: 671
Wisconsin USA
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Bill MeLater Offline
mopar
Bill MeLater  Offline
mopar
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Joined: Nov 2008
Posts: 671
Wisconsin USA
The best way to do this in the car is with a right angle hammer and a left handed tappunch. Weilded properly the broken studs can easliy be driven through into the water jackets and later fished out through the radiator petcock like a kidney stone. Or, you could just pull the head. Entirely up to you.

Re: twisted off exhaust manifold studs on 440? [Re: Bill MeLater] #298391
04/25/09 09:38 PM
04/25/09 09:38 PM

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i broke all 4 studs putting headers on my 318. i just drilled it out, stuck a magnet in the hole to get out all the excess metal, and re threaded it. i had to cut my inner fender wells to do it but it was an easy fix with some sheet metal and pop rivets and actually looks kinda cool.

Re: twisted off exhaust manifold studs on 440? [Re: 61 NYer Convt] #298392
04/25/09 09:45 PM
04/25/09 09:45 PM
Joined: Jan 2003
Posts: 24,562
Brookeville, Md
Mr.Yuck Offline
Not enough dumb comments...yet
Mr.Yuck  Offline
Not enough dumb comments...yet

Joined: Jan 2003
Posts: 24,562
Brookeville, Md
pull the head. take it to a shop and have them do it. It will save you much time and hate

Re: twisted off exhaust manifold studs on 440? [Re: Mr.Yuck] #298393
04/26/09 01:08 AM
04/26/09 01:08 AM
Joined: Feb 2005
Posts: 4,884
Michigan
MNobody Offline
master
MNobody  Offline
master

Joined: Feb 2005
Posts: 4,884
Michigan
Quote:

pull the head. take it to a shop and have them do it. It will save you much time and hate




With 3 to fix this is your best bet.
I had a guy drill out one of mine with a 90 degree drill and he went too deep and drilled into the valve port right above the valve face. Got it all put back together and it would'nt turn over, all 8 cylinders full of coolant from a 3/16" hole.

Re: twisted off exhaust manifold studs on 440? [Re: MNobody] #298394
04/26/09 02:27 AM
04/26/09 02:27 AM
Joined: Dec 2003
Posts: 4,954
northwest USA
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NANKET Offline
master
NANKET  Offline
master
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Joined: Dec 2003
Posts: 4,954
northwest USA
Quote:

Quote:

pull the head. take it to a shop and have them do it. It will save you much time and hate




With 3 to fix this is your best bet.
I had a guy drill out one of mine with a 90 degree drill and he went too deep and drilled into the valve port right above the valve face. Got it all put back together and it would'nt turn over, all 8 cylinders full of coolant from a 3/16" hole.




Shouldn't drink and drill.

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