broken exhaust studs

[angelny911]

HELP GUYS ......here it goes iv'e tried everything to remove broken ehaust studs heating,drilling ,extractors ,with bad results .hate to have to drop motor and take to a shop anyone else have any luck removing studs ....thanks

[JP911]

There's a guy on the forums who made a jig that he sells for just this purpose, but I would think you can make your own. It will make drilling out the studs alot easier. That, and some really sharp bits will get you through it.

[john walker's workshop]

here's one of christian's threads. read it and buy his tool. you can sell it easily when you're done and recoup most of your money if the price freaks you out. well worth it IMO.

A tail of burnt spaghetti and broken exhaust studs.

[Tim Hancock]

Here is an excerpt from when I posted about the drill fixture I made awhile back. It looks kind of crude but works fine.

"I made mine out of a piece of scrap steel and some 1/2-13 short bolts. Drill the center out of a few bolts which form the drill guide bushings (small one for pilot then larger up to helicoil tap drill size).
Make a center plug out of whatever to match the id of your port and countersink it and attach it to the bar with a flathead screw.
Drill an 8mm or 5/16" hole on the other end to slip over an existing stud. This can all be made on a simple drill press, but a lathe is helpful to drill the 1/2-13 drill "bushing" bolts."

[mb911]

I ended up buying the weld up flange from tialsport and then drilled out 1 hole for a drill bushing it was dead on

[JWPATE]

Once the studs are finally out, has anyone had success with replacing them with, say stainless studs, and using copper or brass nuts?