Can anyone suggest a San Diego source to remove an exhaust stud (EDM???)

Rich911E · Rich911E's Garage

Well, in the inevitable tradition of one bolt holding things up, I have one exhaust stud in the 2.7 that just refuses to come out. I checked the archives on the board and everyone seems to use the heat, twist and patience approach with varying results.

After a lot of penetrating oil (almost two weeks worth) and some heat (maybe needs more tonight) the stud just refuses to come out. As tempting as it is to just use a spacer and bolt it up, I know that I will get this engine in the car and bolt up the exhaust only to have that sucker break off from all of the abuse.

So, at the risk of being called chicken and to avoid this additional level of frustration, I am just going to take the longblock over to a machine shop and let them remove it or EDM it out.

I would appreciate if anybody could suggest a machine shop in San Diego (Kearny Mesa???) area that would do a good job of this?

Thanks in advance,

Rich

studeb · 03-12-2003, 10:41 AM

i haven't used them, but for EDM work i was referred to Kenyon Machine, 5002 Sante FE. (858) 270-2610

Targa Dude · Targa Dude's Garage

Rich, the worst that could happen if you continued on..is it would break off..since you already concidered the edm method.. you have nothing to lose.. now get back to work!

Jorge (Targa Dude)

Rot 911 · 03-12-2003, 12:28 PM

Quote:

Originally posted by Targa Dude
Rich, the worst that could happen if you continued on..is it would break off..since you already concidered the edm method.. you have nothing to lose.. now get back to work!

I agree, get that stud red hot then cool a couple of times then first try to slightly tigten the stud into the block then see if you can get it to come out.

jhelgesen · 03-12-2003, 12:42 PM

I've mentioned them before, try a Craftsman Bolt Out set. I've yet to find a stuck bolt or nut I couldn't get out with one of these things.

ted · ted's Garage

Give Black Forest a call, they are in your area.
858 292 1192

Paul Valcourt · 03-12-2003, 03:02 PM

After breaking a couple of studs I removed 3 more that were threatening to break by using a mig welder and welding a nut on the end of them. After the nut was welded and the stud was still hot I put the socket to it and they came out like the head was made of butter. If you know anyone who has a portable mig have them come over and use it on your stud. Good luck with your project.

Rich911E · Rich911E's Garage

Thank you all for the suggestions.

studeb: Thank you for the source on EDM. If it comes to that, I'll take it to Kenyon.

Jorge and Kurt and Paul: I will try the heat and cool method again tonight. I wish I had a real torch instead of propane one, but if it sits on their long enough it should get plenty hot. As you said, if it breaks the machine shop is still going to use traditional methods for removal.

Jhelgesen: I saw the craftsman set and I am glad to hear that they work well, but getting a grip on it is not the problem at the moment (once I break it off it will be!) I just use the old fashioned "jam two nuts together" approach.

Ted: I know about Black Forest and may call them for a recommendation. Thanks for the number.

I'll post tomorrow if it comes out tonight.

Rich

Rutherford · Rutherford's Garage

You have to use oxy acetelene nothing elese will get the nut hot enough.I just went through everything that you are going through 3 weeks ago. I broke off almost every stud after soaking them for a week. Then I attempted to use a screw extractor, and gues what that broke off inside my ex. stud. Eng. had to come out and get EDM machine work. I feel that if I would have used the oxy accetelene first everything would have been avoided but I would'nt have known my clutch disc was on the lining rivets etc.......

Rich911E · Rich911E's Garage

Well, I heated and tapped and heated and tapped and cooled and heated and tapped and tightened and loosened and tapped and cooled and ...

it broke anyway.

Thanks for the help, but luckily it is on an engine stand and can go to the machine shop as is.

Bummer -- I hate this kind of stuff. I love stainless steel.

Rich

Rutherford · Rutherford's Garage

Edm works well after I went through that I went out and bought oxy accetelene set. I feel it is a must have item for any exhaust work and when I put in my new studs I antiseezed them up and only torqued them to 5 ft. lbs. Learn and live in that 101 porsche project book they show a Porsche dealership with a mobile almost bridgeport machine for drilling exhaust studs under a 911 on a lift, also there is a contact for edm work through that book I would give it to you, but the books 100 miles away from me right now.