Broken exhaust studs

[pkabush]

I got a really good deal on some B&B headers w/ heat a few months ago. They were so cheep and in such good shape I couldn't afford not to buy em.
My car had B&Bs when I bought it over 10 years ago but they're in pretty rough shape.
Anyway I set some time aside for the swap last Saturday thinking I'd soon be tearing up the streets with my shiny new headers by evening.
Not so much. After liberal soaking the nuts with PB Blaster Thurs. & Fri. I gave the first one a shot. Snap goes the stud.
Time to get out the impact gun... Snapped the second one. OK I,m gonna need heat.
Got it red hot, waited about 30 seconds, put the impact gun to work, bap, bap, bap
and.... snap.
I'm now 0 for 3 and seriously rethinking my "great deal". In fact I'm starting to wonder if I shouldn't just bite the bullet and limp it over to John Walker.
Time for a break. So after much reading here on the board three things became clear.
One, I,m in good company. Seams like most who tempt fate with exhaust studs lose. Two, I'm gonna need a jig to drill out the broken studs. And three, I'm way to stubborn and far to cheap to take it to a shop.
So, I tried my luck again tonight after work and to my surprise and delight I managed
to get two of the nasty buggers off with lots of heat and the impact gun. Problem is the six remaining nuts can only be reached with a wrench so, no love from the impact gun. First try w/o the gun resulted in another snapped stud.
Any help here is greatly appreciated.
Also, I'd be stoked if anyone has a jig they would be willing to rent.

[smurfbus]

Outch, sounds like a nightmare. If i ever need to remove my headers it will be after the season so I have all winter to swear on them. Most recommend a snap on stud removal kit if there is some stud left to grab on. That is easier after the headers are removed of course so more studs to possibly brake.

[slow&rusty]

I went through the same anguish not that long ago when I installed Brian / RARLYL8's beautiful headers in my car (I had B&Bs that I removed to install Brian's set-up).

My exhaust studs were the original and 24 years old and I ended snapping 2 studs in total, which made my heart sank. It made me wonder why the heck did I even touch them and felt like the devil on my left shoulder saying "I told you so...I told you so".

As I am never the person to never give-up and admit defeat (stubborn) and like you I always work on my car at home I persevered through it.

Here is what I did:
Generous Heat and an Irwin stud extractor coupled with my 1/2 impact and all other 10 studs broke free all within an hour or less, I should have tried this from the get-go:


The Irwin stud extractor has to be hammered onto the stud to "grip-it" so once you do that you are committed as the threads on the stud will then be ruined:


The heat (MAP Gas), coupled with a few whacks with a 5lb sledge and the hammer action of an impact and voila:


Broken studs on left:


Operating table:


Yasin

[krasuskyp]

just damn

damn wish I'd read 'bouts yerses impact tricks back when I broke one or 37 forget whilst installing my Powerhauses

"gooooooood tiiiiiiimes"

not

I think I've learned to repress that into happy stuff - oh look a butterfly...

we did use every other trick known to man, wish I'd thought of ze obvious - tho it's counterintuitive to a degree as I'd too think they'd just snap immediately

great it worked out for you both, thanks for sharing

[M5guy]

This thread explains in explicit detail the reason why I have never put headers on my 930...

Glad it all worked out for you all in the end.

[slow&rusty]

I agree guys, but to M5Guy's point...this picture made it worth the weeks and weeks of torment (with all brand new gaskets and ARP stainless studs / fasteners):

[krasuskyp]

ohmydearfukkinlord



oohhhhhhhhh woooooooooooooow

nicely done Yasin

And to M5guy's point

yeah, this thread could certainly be used as header deterrent.

I'll however add that

headers

were the single

best friggin thing done

to 'right' my stock 930.

Worth it if I'd snapped each stud, twice.

yep.

[pkabush]

Thanks for the reply's guys.
Yasin, it looks like you had good success with the Irwin extractor. Where did you get it?
I can see why you ditched your B&Bs. I'm not loven the design. I may sell both pairs and get a set of Brian's. We'll see. I could probably drive it to John Walker now but if I go any further that won't be an option. Not looking forward to having it towed and paying to have the work done on top of that. I'm just hoping I can get the studs out with an extractor.
Oh the joy. At least they all broke at the nut so I have some meat to grab

[slow&rusty]

Yup the Irwin Tool extractor worked great but as mentioned it was in combination with the MAP Gas heat and the hammer action of the Impact.

I bought the set for $15 or so at the local Northern Tool Outlet, if you are interested I can buy a set and FedEx it to you or try eBay there are a few sets for sale on there.

You are lucky the stud sheared off at the nut and not flush with the head..which happened to me...which took curse words in conversation to a whole new level.
Good luck,
Yasin

[Ken911]

I just gave up and drilled everything and time certed it. Had them off several times since always was easy after that.

[slow&rusty]

Originally Posted by Ken911

I just gave up

What is this "giving up" you speak of Ken?

[speednme1]

What about the Stomski, as sold by our host EXHAUST HEAD STUD REPAIR KIT

[Ken911]

I just snapped them off drilled them out and timecerted all of them. I have that jig for drilling them out that I boughthere.

[pkabush]

Thanks Yasin. I'll let ya know how this pans out.
I hope I don't need to drill but if I do I'll have to go the Stomski route, or something similar.
There was a guy on the board who fabbed those up with his CNC mill but I'm not sure he's still doing it. His were a little over $100. John Walker bought one and was quite happy with it, I believe he designed it as well. I figure if it's good enough for his shop it's more than adequate for my ham fists.
I'd way rather put that $ into the car though

[krasuskyp]

having the nub remain doesn't guarantee extraction unfort 8-/

of my 4, we busted 1 down a couple times until it was flush - this using double nut, a welded nut, heat, PB blast, genie seyance, Ouija Board, black magic, voodoo, prayers to Gods & Demigodz - everything.

everything,

'cept impact. D'oh.

Hope that works for you, or that kewl extractor bit

my machinist bud drilled it for me using E-Man's loaned Jig, and timecert'd

Now, back to my Happy Place - whereby I attempt to lobotomize / exorcize all recollect of such funfun timez... crykie.

[Ken911]

My Spare set of heads that I have for the efi had about half of them bust when I was pulling them to clean up. So even that set of heads I went ahead and put timecerts in every exhaust stud hole to prevent future problems.