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Use Old HE Flange for Drill Jig?
I have a broken exhaust stud that I need to drill out. Any thoughts on cutting off the flange from the old heat exchanger and using that as a guide to drill out the stud. I have an 83 which uses the sleeves on the flange, so it would essentially be locked in place and centered like the guide tool. Any thoughts?
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Matt. 83 911SC 85.5 944 NA - Sold |
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10-07-2011, 11:55 AM
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Mo money = mo parts
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Sounds like worth trying. You may want to put a bolt in the opposite side to stabilize it if both sides are not broken. I would also think about inserting a bushing in the HE hole on the side you are going to drill and start with an undersized bit. Last suggestion, try to find reverse bits. As you get deep enough, it may have enough bite into the stud to back it out.
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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" |
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10-07-2011, 12:32 PM
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Hardened inserts
Sears sells a set of drill bit stops that slide over the drill and fasten with a set screw. The stops are made of a hardened steel and make a good insert for drilling a pilot hole. Good luck with your project!
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FEC3 1980 911SC coupe "Zeus" 3.3SS god of thunder and lightning |
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10-07-2011, 02:07 PM
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Location: Marysville Wa.
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the hole is too big to accurately guide the drill bit. it's ballpark at best.
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https://www.instagram.com/johnwalker8704 8009 103rd pl ne Marysville Wa 98270 206 637 4071 |
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10-07-2011, 02:33 PM
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Yes it can be done. I did it and it worked perfectly.
I made some guide pilots to make sure that you are centered and running straight. I tapped the one side for the appropriate bolt size to match the hole size in the flange. Then took two grade nine bolts and drilled a hole through the center of the bolts. One hole was a smaller diameter than the stud to give me a pilot hole in the stud to start the final drill in the proper line. The first bolt was used to drill a smaller pilot hole in the broken stud so that you will get a perfect start with the final drill size. Then changed the bolt to the final size and drilled out the stud. It worked perfectly as I said before.
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Gary Kozun 83 911SC Cabriolet |
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10-07-2011, 08:03 PM
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Doesn't Stomski Racing make a really cool kit just for this very purpose? John
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10-08-2011, 01:44 PM
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Quote:
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Matt. 83 911SC 85.5 944 NA - Sold |
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10-08-2011, 02:38 PM
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having done this when installing SSI's and again on Heads that were redone but old studs were left in and then broke off.. I will assure you that the Christian made tool is the best money you will spend... and worth the wait...
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83 SC Targa -- 3.2SS, GT2-108 Dougherty Cams, 9.5:1 JE Pistons, Supertec Studs, PMO ITB's, MS2 EFI, SSI's, Recurved Dizzy, MSD, Backdated Dansk Sport Stainless 2 in 1 out, Elephant Polybronze, Turbo Tie Rods, Bilstein HD's, Hollow 21-27 TBs, Optima Redtop 34R, Griffiths-ZIMS AC, Seine Shifter, Elephant Racing Oil Cooling. |
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10-08-2011, 03:56 PM
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I am waiting for my drill jig from Christian, which I will hopefully receive this week. One question, comes to mind as i think about the procedure in my head. How do I know how deep to drill?
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Matt. 83 911SC 85.5 944 NA - Sold |
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10-19-2011, 05:25 PM
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Matt;
Remove one of the good studs and measure the depth. Then put tape or a stop on the bit allowing for the depth of the stud and whatever tool you have. Simple.
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Gary Kozun 83 911SC Cabriolet |
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10-19-2011, 07:49 PM
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So I drill right down to the bottom of the stud, or do I hold back slightly to ensure I don't hit the bottom of the head?
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Matt. 83 911SC 85.5 944 NA - Sold |
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10-20-2011, 01:35 AM
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Matt;
I put my stop to the bottom of the hole. I measured the strud and the hole. The stud engagement was shorter than the hole so I decided to go to the full depth of the hole ensuring that I would get 95% of the stud. Don't forget that the drill has a taper on the end and if the stud were at the bottom of the hole you could not drill through the stud all the way if your stop is at the bottom on the hole. You would have to go into the head by the depth of the taper on your drill bit to go through the stud. There is still plenty of meat in the head to do this so I would not worry about it to much.
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Gary Kozun 83 911SC Cabriolet |
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10-20-2011, 07:54 AM
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Ok thanks. Last question...I hope. Do I need a left hand drill bit or can I do this with a regular one? I cant find a left hand bit locally.
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Matt. 83 911SC 85.5 944 NA - Sold |
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10-20-2011, 09:16 AM
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No more than 7/8" deep........
Quote:
Matt, I used 7/8" to 1" depth for the exhaust studs. I would suggest to use a 7/8" depth-guide for replacing broken or worn out exhaust studs. Do you still need the exhaust stud jig? I'll lend my set to you provided I get it back (and it's not for sale). Last time I lend it to a member from CA, he gave me a deposit more than the value of the jig. The first jig I had was never returned to me by a fellow member. So you know how I feel about losing a second one. PM me if you are comfortable with the arrangement. Tony |
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10-20-2011, 10:15 AM
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Quote:
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Matt. 83 911SC 85.5 944 NA - Sold |
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10-20-2011, 10:34 AM
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Grand Am/IMSA Data Guy
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I recommend not using an "easy out" after you drill the stud. Mine broke off in the stud. What a nightmare to grind away the "easy"out with a dremel and not ruin the head. Engine still in the car and on jack stands, lots of bad words!.
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Jerry Austin AIM Data Products Dealer 84 911 3.6 track car - Sold Morris Minor Van with S2000 running gear http://austinmotorsportsllc.com/ |
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10-20-2011, 03:19 PM
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Quote:
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Matt. 83 911SC 85.5 944 NA - Sold |
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10-20-2011, 04:07 PM
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I received my tool from Chris today. So I started drilling. I drilled out the stud and this is what I'm left with. I cant tell if I still have pieces of the stud in there or do I need to run a tap through it.
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Matt. 83 911SC 85.5 944 NA - Sold |
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10-27-2011, 05:37 PM
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You need to pick out and/or unwind the remaining metal that is within the threads.
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Mark '83 SC Targa - since 5/5/2001 '06 911 S Aerokit - from 5/2/2016 to 11/14/2018 '11 911 S w/PDK - from 7/2/2021 to ??? |
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10-27-2011, 07:00 PM
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Quote:
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Matt. 83 911SC 85.5 944 NA - Sold |
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10-28-2011, 01:32 AM
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1983 Porsche 911SC
1986 Porsche 911
Zeus (god of thunder and lightning)
1984 Porsche 911 964 3.6
