Broken Exhaust Stud tool- any lenders?

[Packy]

Can anyone PLEASE please please please lend me an exhaust stud removal tool?

I went to install a set of SSIs today and broke two studs. And I still have 4 soaking in penetrant waiting to be broken .

Anyhow, I would prefer not to spend $270 on a fancy anodized tool i'm only going to use once.

I would be extremely appreciative.

Thanks,

-P

[JJ 911SC]

Are the studs broken flush with the head? If they are not you can removed them easily with a stud extractor and an impact gun. You need about 1/4" as a minimum.

Since you already broke a couple, you should consider cutting through through the nuts of those remaining so it leave you lots to fit an extractor on them.

[boyt911sc]

Originally Posted by Packy

Can anyone PLEASE please please please lend me an exhaust stud removal tool?

I went to install a set of SSIs today and broke two studs. And I still have 4 soaking in penetrant waiting to be broken .

Anyhow, I would prefer not to spend $270 on a fancy anodized tool i'm only going to use once.

I would be extremely appreciative.

Thanks,

-P

Packy,

How urgent do you need to the kit? I'll be in Carmel, CA for the whole month of August. I could bring the set and lend them to you provided that you would return them. I lost one set before to an acquaintance 2 years ago. PM me for details.

Tony

[Packy]

@JJ The studs broke off flush to the bottom of the manifold flange so I have some threads to work with. I've heard about these things breaking off twice though. Do you have a link a stud extractor? I don't want to ruin the female thread in the heads.

@boy I can wait a little while. I'll be gone through the first week of august. If you'll be around I can definitely take care of what I have to do while you are here. I could pick it up and drop it off before you leave. That would be AWESOME!!! I don't expect to take more than one or two hours a stud. I'll shoot you a PM.

[JJ 911SC]

Packy

Broke twice... The one I had to drill out broke 3 times

OK, this morning I spend some time trying to get the thread that I started (maybe not) about how to remove them with the impact gun. Off course I could not find it but I will If not, I'll repost the photos.

Now, I end up drilling the flushed stud without a jig. I broke 2 drills bit in the hole as well as a screw out That is not fun to drilled out using a dremel like tool.

While my story turn OK, I would not recommend to try this at home Spend the money on the jig or wait for someone like boyt911sc to offer.

The extractor is the piece on the right (top row) on post #8 of; http://forums.pelicanparts.com/porsche-911-technical-forum/592476-help-exhaust-stud-drilling.html

I got 7 of the studs out using the extractor and the impact gun as mentioned in post 8 of the link above.

The rest of the thread shows what I had to do for the one that broke flush.

That said, since its not broken flush, I would try to removed it with the extractor. The key is to start with a low pressure and work your way up and out.

I'll post photos (or the thread) soon.

JJ

[boyt911sc]

Packy,

I added the 'exhaust stud kit' to the list of things to bring on my vacation to California. I'll be in Carmel near you on the 5th of August and will be staying there till the last week of the month. I'll give you a call when I get there and will arrange a meeting place between Carmel and Santa Cruz. Glad to assist fellow 911 enthusiast.

Tony

[Packy]

Man YOU. GUYS. ARE. AWESOME!!!

Tony, talk to you soon.

JJ, thanks for the info. I'm going to work on it until I get the tool from Tony.

[boyt911sc]

Packy,

Do you have a 17/64" carbide drill bit in your arsenal? You need a sharp drill bit to make a clean drill out of the old/broken exhaust studs. Is the engine on a engine stand?

Tony

[JJ 911SC]

OK found the pics

This is a straight in line stud extractor. They seem hard to find, the place I got mine from does not carry them anymore and no result from Google!!!

Found it... http://www.toolsupplycenter.com/cutting-tools/1382-STUD-EXTRACTOR-FOR-3-8-INCH-IMPACT.html

[Flat6pac]

I got one of those extractors a few weeks ago off Amazon for $20 vs Northern Tool for $30+tax

Bruce

[Packy]

Originally Posted by boyt911sc

Packy,

Do you have a 17/64" carbide drill bit in your arsenal? You need a sharp drill bit to make a clean drill out of the old/broken exhaust studs. Is the engine on a engine stand?

Tony

No, my car is jacked up and I'm doing everything under the car. I figure I'd be okay drilling them out with the fixture. And gravity could possible help keep chips out of the hole. I don't really know what is on the far side of the stud in the head. I'm reading up on Stomski Racings instructions here (they make the pelican kit).

I'll be removing the rest of the studs tonight that have been soaking in penetrant so I'll know exactly how many studs to order from Pelican. They are cheap so I'll probably order more than I need.

I'll also order a few 17/64 bits from McMaster-Carr. I'll probably get a few 1/8" bits as well for pilot holes. I'll get a 8x1.25 tap if I don't have one already. I have to check on that.

I'm getting excited to get that exhaust on.

[Packy]

Hey JJ, how many studs did you brake when you used the stud extractor? I'm thinking I'll just leave the studs in that didn't brake instead of risking shearing them off. Ideally I would like to replace each stud with a new one but that may not be the smartest decision right now.

[boyt911sc]

Originally Posted by Packy

Hey JJ, how many studs did you brake when you used the stud extractor? I'm thinking I'll just leave the studs in that didn't brake instead of risking shearing them off. Ideally I would like to replace each stud with a new one but that may not be the smartest decision right now.

Packy,

If I were you, this is the time to replace those old exhaust studs. BTW, do you have an air compressor? You could try to remove the old exhaust studs with an impact wrench using a Snap-On stud extractor (8 mm x 1.25). I could bring it too in case you decide to proceed with the suggestion. If some break during extraction, then use the tool for drilling out. Think it over.

Tony

[trak ratt]

If threads are good, double nuts work well. I ended up having to weld a nut on the extract. Friend did the welding after I failed twice to get it right. Easier with motor out. Motor extraction is pretty easy too. Would let you do some other stuff at the same time.

[Targalid]

Packy,
For what it is worth, I recently removed the thermal reactors from my 76 using the method preferred on this forum: I heated the nuts with an acetylene torch to a dull read heat then, while still red, quickly gave them a quarter turn with a wrench (gloves used here). At that point they turned off easily without a single broken stud. I don't know whether you absolutely wanted to replace the studs or not. I did not.
Al

[Packy]

Originally Posted by boyt911sc

Packy,

If I were you, this is the time to replace those old exhaust studs. BTW, do you have an air compressor? You could try to remove the old exhaust studs with an impact wrench using a Snap-On stud extractor (8 mm x 1.25). I could bring it too in case you decide to proceed with the suggestion. If some break during extraction, then use the tool for drilling out. Think it over.

Tony

I was leaning toward replacing all the studs anyways and was on the line, but by the way it sounds now is as good a time as any. This will make my life easier every time I need to pop on the old exhaust for smog.

Tony, that would be awesome if you could bring the extractor with you as well. I owe you. I don't know what I could do to repay you, but I'll think of something. Until then, I'll try track ratt's double nut method.

Thanks again guys.

[boyt911sc]

Originally Posted by Packy

I was leaning toward replacing all the studs anyways and was on the line, but by the way it sounds now is as good a time as any. This will make my life easier every time I need to pop on the old exhaust for smog.

Tony, that would be awesome if you could bring the extractor with you as well. I owe you. I don't know what I could do to repay you, but I'll think of something. Until then, I'll try track ratt's double nut method.

Thanks again guys.

Packy,

I used the Snap-On stud remover for the cylinder heads and exhaust studs removal. It would take a few seconds to pop each stud. I started with medium torque (middle setting) to prevent breakage and everyone came off nice and easy. I was expecting the exhaust studs to break but was totally surprised I did not have one. So it was an easy project. The worst scenario is that the exhaust stud/s snap and broke. So what!!!! You got the exhaust stud tool available.

BTW, do you have an air compressor? You need that for the Snap-On 'stud dowel remover' and an impact driver. Pictured below is the 10 mm x 1.5 collet used for the head studs removal. The exhaust studs would need an 8 mm x 1.24 collet.


Tony

[JJ 911SC]

--------------------------------------------------------------------------------

Originally Posted by Packy

Hey JJ, how many studs did you brake when you used the stud extractor? I'm thinking I'll just leave the studs in that didn't brake instead of risking shearing them off. Ideally I would like to replace each stud with a new one but that may not be the smartest decision right now.

Originally Posted by boyt911sc

Packy,

If I were you, this is the time to replace those old exhaust studs. BTW, do you have an air compressor? You could try to remove the old exhaust studs with an impact wrench using a Snap-On stud extractor (8 mm x 1.25). I could bring it too in case you decide to proceed with the suggestion. If some break during extraction, then use the tool for drilling out. Think it over.

Tony

Packy

This is the way to go. Remove them all.

Listed below is the story of my studs.

The one I had to drilled out broke 3 time before it end up flush with the head... Such is life, it build caracther Yes I was $hitting brick as I was doing my first ever tap into a Porsche cylinder head

Your are some lucky as Tony has the extractor and you'll be getting "almost" free help; got the feed and lube the help after the job his done

Keep the stud wet with PB blaster until Tony stop by and it will be a piece of cake...

Here is the story of the 12 studs;

2 studs came out with the barrel nut
2 barrel nuts came out clean
2 barrell nuts snap right at the end of the nut

I cut out all the 6 nuts

Of the 10 Studs lefts standing in the head;

7 come out using a stud extractor and a air gun starting at 30 pounds, increasing to 40 and they came out at 50.


1 broke once but with 1/2" left, we (me and Alex) got it out.

It left two to get out. We put the extrator to one and it broke but left the flat part, so we grab that and I swear it start it to turn but snap flush, that is the one that I drilled out.

Due to the location the last one, another half broken stud on cylinder # 3, I could not use the big extractor so I decided to used a Bold Out (Sear kit). Low and behold it did come out.

[boyt911sc]

Patrick,

You have not confirmed my inquiry to you earlier. Do you have an air compressor and an impact wrench? The broken exhaust stud tool is all set and packed in my check-in luggage. The Snap-On stud remover, M8 x 1.25 collet, and socket are ready for your project if you got the required equipment. Leaving for CA next Friday (august 5). BTW, could you PM me your address in case we have conflict with our schedules? Got your phone number already. Please advise.

Tony

[Packy]

Hey Tony, I do have a compressor and an impact wrench. Sorry it took me so long to get back to you. I get back to Santa Cruz today. I'll send you a PM now.