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911mot 911mot is offline
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Join Date: Sep 2004
Location: Watford UK
Posts: 828
Is it OK to heli-coil an exhaust stud?

Ive been having major grief with one of my exhaust studs.
It broke becuse I didn't heat the nut so I center punched and drilled out the remains. Started OK with a 3mm pilot and the gradually went up .5mm in drill size till I could see the original thread. Great I thought, now I'll just clean it up with a thread restorer. I must have been rushing because I managed to snap it off in the head. Cue wrench being launched at high speed into garden. Next day I drilled out the broken bit and got to a similar stage as last time, only this time I tapped the hole with an M8 tap. Screwing the new stud in seemed OK at first but as soon as it 'bit' and I applied some torque it stripped the thread.
So what should I do now? Should I tap it slightly larger for a bigger stud, or will a heli-coil insert get me out of this one?
Thanks for your advice.
1984 3.2 Carrera

Impact Bumpers on track:
Old 02-17-2005, 02:44 PM
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