Pelican Parts
Parts Catalog Accessories Catalog How To Articles Tech Forums
Call Pelican Parts at 888-280-7799
Shopping Cart Cart | Project List | Order Status | Help



Go Back   Pelican Parts Forums > Porsche Forums > Porsche 911 Technical Forum


Reply
 
LinkBack Thread Tools Rate Thread
Author
Thread Post New Thread    Reply
Registered
 
egertk's Avatar
 
Join Date: Jan 2008
Location: Lynnwood, WA
Posts: 189
Garage
Multiple Broken Exhaust Studs

First off I've got the jig to drill out the studs. My issue is I have both studs broken off on a couple of ports, so I have no way of bolting the jig down. Any suggestions?

Old 01-28-2010, 01:27 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #1 (permalink)
Registered
 
Join Date: Feb 2006
Location: Scottsdale, AZ
Posts: 6,758
Garage
I did that on one of my ports, I was able to get the jig tight into the exhaust hole and worked really carefull to line the drill hole up, as long as you are careful and keep checking you should still be able to get the bit started, use plenty of cutting fluid and check your work frequently.

Or..you could start with a smaller drill bit and get it started ensuring you are dead on center.

Is the engine still in the car? What jig are you using? Is it the one from Christian?

At worst you may have to drill, put inserts and re tap the holes.
__________________
78’ SC 911 Targa - 3.2SS, PMO 46, M&K 2/2 1 5/8” HEADERS, 123 DIST, PORTERFIELD R4-S PADS, KR75 CAMS, REBEL RACING BUSHINGS, KONI CLASSICS
Old 01-28-2010, 01:49 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #2 (permalink)
Registered
 
80-911SC's Avatar
 
Join Date: Feb 2009
Location: STOCKTON CA
Posts: 2,124
Garage
left hand drill bit and one size small may be the trick if you can't clamp very snug ...
and as the other poster ???'d motor in or out ? if out you could rig an angle iron with bolts spread and a bore hole in the center and cross clap down to lower legs of engine stand or to bench if bench mounted ........
Old 01-28-2010, 05:50 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #3 (permalink)
Registered
 
egertk's Avatar
 
Join Date: Jan 2008
Location: Lynnwood, WA
Posts: 189
Garage
The motor is still in the car...
Old 01-29-2010, 09:24 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #4 (permalink)
Somatic Negative Optimist
 
Gunter's Avatar
 
Join Date: Mar 2002
Location: Winlaw, BC, Canada
Posts: 7,206
Garage
Motor still in the car presents a few problems but can be overcome.

Carefully grind the stud flush, make a deep mark with a center punch in the center of the stud.
Drill with appropriate size drill (Left or right) making sure that the drill doesn't wander.
If it does, stop, go to the opposite stud and repeat.
Staying in the center and keeping the drill straight is critical.

You have to find a way to get enough push behind the drill motor so the drill can make chips.
Finish one hole, install a new stud, install the jig and finish the other side.

Protect your eyes!
__________________
1980 Carrerarized SC with SS 3.2, LSD & Extras. SOLD!
1995 seafoam-green 993 C2, LSD, Sport seats.
Abstract Darwin Ipso Facto: "Life is evolutionary random and has no meaning as evidenced by 7 Billion paranoid talking monkeys with super-inflated egos and matching vanity worshipping illusionary Gods and Saviors ".
Old 01-29-2010, 09:49 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #5 (permalink)
Mo money = mo parts
 
Join Date: Jul 2003
Location: Pittsburgh, PA
Posts: 1,198
Garage
I just replaced all the exhaust studs on my car, but my circumstances were better that what you are describing. The engine was out and only one of the studs was broken off. You didn't state if they were broken flush with the head or if they were sticking out enough to allow you could get any type of grip on them.

If they are nearly flush, I agree with Gunter that you need grind the edge flat, then hit the center with a punch. Hitting the center is THE key step. Even if you use the jig, you need to hit the center with a punch. I am not sure how much value the jig will be unless you can tighten it down. The hole for the bit on the jig is almost the same size as the stud, so you have to be almost perfectly centered not to hit the female threads in the head. I was successful at drilling mine but ended up having a helicoil installed because my tap seemed to be slightly wider than the stud and couldn't get the stud tight. Drilling is much more work and higher risk, but sometimes it's the only option.

I would only drill if you don't have enough stud protruding to get vice grips on it. I actually had to get two pairs of vice grips on mine because a single pair kept spinning. The stud needs to be cherry red, MAPP gas is a good option. If you can get it to move at all, stop and reheat the stud, turn, repeat as necessary until the stud is nearly out.

Top End and Reseal
__________________
Greg

86 Coupe (stock - pretty much like Butzi designed it) - gone, but not forgotten
65 Ducati Monza 250 & 66 Monza Junior (project)
"if you are lucky enough to own a Porsche, you are lucky enough"
Old 01-29-2010, 05:35 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #6 (permalink)
 
Registered
 
80-911SC's Avatar
 
Join Date: Feb 2009
Location: STOCKTON CA
Posts: 2,124
Garage
not to doubt the vice grip idea but if it sticks out far enough to grab with vice grips why wouldn't you use a stud remover that is made to grab something round and you can still use a torch to heat assist just tighten remover , heat , insert ratchet and turn .....

Or the other way to make it easier .......take the motor out. there has to be something on you "when I need to take the motor out I should do __________ list"

Old 01-29-2010, 07:16 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #7 (permalink)
Reply


 


All times are GMT -8. The time now is 10:01 AM.


 
Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2025, vBulletin Solutions, Inc.
Search Engine Optimization by vBSEO 3.6.0
Copyright 2025 Pelican Parts, LLC - Posts may be archived for display on the Pelican Parts Website -    DMCA Registered Agent Contact Page
 

DTO Garage Plus vBulletin Plugins by Drive Thru Online, Inc.