exhaust stud removal

[kepperly]

I am about done w/ my heads, new guides, valves, springs, cleaned ,blasted and almost ready to go back on. the last old
exhaust stud broke( amazingly the only one). I have the head
where I can basically do any type of stud extraction but at this point I don't want to screw up the head. What are the boards
suggestions for the best head off method.

Keith Epperly
87 slant nose turbo look carrera cabriolet

[john walker's workshop]

the best way of course is to buy or borrow christian's stud drilling tool. several folks here have bought one and it's just sitting in their toolbox. other than that, be sure you drill real straight and perfectly down the center of the stud. a pilot hole first, then a 17/64, which if dead center, will leave just the threads. that's the beauty of "the tool". they rarely just unscrew, so odds are you'll be drilling. you can also use a timesert insert after drilling out the stud, threads and all. the timesert kit has the proper drill size, tap and installation tool for the inserts. helicoils suck, IMHO.

[rlane]

Keith, I have Christians toll, and as JW says it is sitting in the "Special Tools" drawer. I'd be glad to lend it to you with assurances it gets back (IT IS A really NICE PIECE OF WORK) You will need a good 17/64 bit, carbide is best. Let me know if you want to borrow it.

[kepperly]

RICHARD,
YOU ARE THE MAN, IF YOU WOULD LIKE , I'LL PM THE SHIPPING
INFO AND DO THE JOB THE SAME DAY IT ARRIVES AND FED EX AIR IT BACK THE FOLLOWING DAY. ( I KNOW HOW THOSE SPECIAL DRAWERS IN MY TOOL CAB FEEL WHEN EMPTY)

KEITH EPPERLY C/O
OVERSEAS CAR SERVICE
342 N. WASHINGTON
WICHITA, KANSAS 67214
HOME- 1-316-733-8511
WORK- 1-316-264-8414
CELL 1-316-734-3543
FAX- 1-316-264-3151

PLUS A SURPRISE INCLUDED IN THE PACKAGE

[casperlabs]

Keith,
It sounds like your heads are still loose. If so, I would recommend removing the broken end on a vertical milling machine. This way there is no chance of not being vertical, slipping off the centerline, or going too deep when drilling. Any of the Porsche specialty engine o/h shops will have a fixture to hold the head on the mill for this operation, as it is such a common problem. We have one too, and can usually pick up the first thread with the tap. If we find the hole is already chewed up, we have stainless steel KEENSERTs that eliminate oxidation/corrosion completely if used with one of our high temp alloy studs (for exhaust pipe flanges up to 11mm thickness only). We charge $15 to remove the first stud and $12.00 for each additional (plus shipping). If you need help call us 561-575-3157

Bill Ryan
Casper Labs, Inc.