HE Install - Broke an exhaust stud! What now??

on-ramp · 11-25-2005, 10:26 AM

Tried to remove the exhaust nut and the stud broke off into the nut. Car is 1983 911SC.

what should I do now before continuing? what's the repair for this.... thanks.

Joeaksa · 11-25-2005, 10:27 AM

The best thing you will ever do on the forum to get info fast.

Do a search and you will find loads of information a lot faster than waiting for people to post. There is even one gent here who has built a jig to drill the stud out and put a new one in.

Get going!

JoeA

PS, if you feel the nut tightening up as you remove the rest, heat is your friend. Heat them up before removing and it may save the other studs.

North Coast Cab · North Coast Cab's Garage

PM A Quiet Boom
He machines an awesome tool set-up just for this. I have one and it's great. I think he has them on eBay.

John

on-ramp · 11-25-2005, 10:46 AM

what does it do? just drill and tap and new hole where the stud was?

on-ramp · 11-25-2005, 07:07 PM

when you remove the old stud, is there an internal thread on the block where the stud came from. Can this be used with a hex bolt to tighten the HE?

Shuie · 07:25 PM

The stud is on the port side of the head. There is no threaded block. You are okay, just dont break the other one on that head. You are going to need Christian's tool and you will have to drill it out and install a new stud. You might get really lucky and still be able to use the existing threads. Worst case is having to go up another bit size and using a helicoil tap kit to install the new stud.

Does anyone sell a fixture for drilling broken exhaust studs

Wil Ferch · 11-26-2005, 09:13 AM

Have heard that some outfits with EDM ( Electro Discharge Machining) capability even come to your house.... and take care of it while it's still in the car...

spendy.... !!!

- Wil

crashmy911 · 11-26-2005, 10:47 AM

Did you drop the heat exchangers yet maybe you still have enough to get a hold of it and turn it all the way out. Use heat and take your time.

on-ramp · 11-26-2005, 11:45 AM

i'm going to countersink the HE hole (create access to stud threads), then use a threaded 8MM standoff and create a taper on one end.

89turbocabmike · 11-26-2005, 12:15 PM

On-ramp, what was your process for removal? Did you use heat? It would help us guide you further. Are you at the point where just one is broken and the headers still on the car? If your at this point, it would depend on your sense of adventure. I just went through this myself. I normally would use heat, but after soaking with pb blaster and on the suggestion of one of my turbo friends, I used my impact without heat. worked fine for the first 4 and then broke one flush with the header flange. I then used heat and my breaker bar and broke one. My success came using heat and the impact. I have a full size acetylene set-up but that is overkill for this situation. Most home improvement stores have a small torch set-up that uses small propane/mapp and oxygen tanks. These are ideal as they have enough heat for the nuts and are easy to manage (torch in one hand, impact in the other) without setting everything afire

. It isn't strong enough though in my experience to remove the studs from the aluminum heads though, not enough heat.

Here are the tools I use with the impact:

Christian's (A Quiet Boom) tool on the head:

This first hole I had to helicoil because I tried to hand drill the threads out last Sunday nite because I didn't have Christian's tool! Christian made me a second body with drill guide for the 21/64 hole for the helicoil. Luckily I had been close by hand and with Christians tool the hole completely cleaned up and was perfectly perpendicular. Came out nice:

This second stud I had Christians tool, hear is the stud with the inside drilled out. You can see the stud threads left in the hole:

Voila, threads unwinding from the hole, and it came out in one peice to boot!

Threads were completely undamaged and new stud installed:

Here are the two tools and inserts from Christian along with the threads from that second hole:

Special thanks to Christian for building and shipping my tool set overnight! Great customer service and support.

Cdnone1 · 11-26-2005, 01:55 PM

Anyone have a link to Christians tools?
Steve

North Coast Cab · North Coast Cab's Garage

Search eBay for exhaust stud. His handle is something like 415w.

John

A Quiet Boom · A Quiet Boom's Garage

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1,1&item=4593976381&sspagename=STRK%3AMESE%3AIT

My handle on ebay is 410w, it's a throwback to my drag racing days before I saw the light I bought a 911! I had a Mustang with a bored and stroked 351w (4.040" bore and 4.000" stroke = 410cid) putting out somewhere around 650hp on the motor alone. Ten second quarter mile times are fun but simply can't compare to the ride I got around Mid-Ohio last year (Thanks John!)