Headstuds Broken at the Case - Worst Case Scenario?
 

Finally found a welder I trusted to attempt to weld nuts on the final two broken headstuds. The studs crumbled where they had been welded (including the stud that stripped out my Snap-On serated collet). I am left with a very uneven surface very close to the case. I believe I am now a candidate for EDM or drilling these final two. Before I do anything, I want to make sure of the following:

A: I now MUST split the case.

B: The preferred method of removal is (EDM) (Drilling)

C: I live in Central Texas, Where is the best location to take the motor?

Thanks again for everyone's help!!

David
'83 SC Targa
@#$#@#$&**(&$%@##!@#*& Head Studs

David,

I feel your pain. I broke a stud on my 77 after 5k on a rebuild. I consider myself lucky as it was a top stud. I did not want to take it apart again so I pulled the motor, injection and fan shroud. It was also broken down by the case. I used a Dremel tool with a cut off disc and cut a grove in the remaining piece. I heater the area with a torch. After a few more pieces of the stud broke off and a few more groves cut into the stud I got it out with an impact driver and alot of luck. That was a good day!!!

A. I would not split the case unless it has alot of mileage. The SC bottom ends are strong.

B. I think drilling is the last option. I would burn it out first. Or at least super heat the area and try my method.

C. ???

Good Luck.

David,
Mayo Performance, in Euless, is run by one of the foremost Porsche experts in US, or so I've heard. My son used them for a PPI last fall, and gave a glowing recommendation for Ed Mayo. Go to Platz Mall and click on 'Service Centers' button for listing of P-car shops (several each in D-FW and Houston areas, one each in Austin and San Antonio).

One other idea is to visit the Waco Harley dealer and see if they can recommend someone.

Suffered a little set back, huh? I explored most of the FMs between 6 and 84, within 40 miles westward, a couple of weekends ago. 160 miles within 3 hours only hints of the fun (lots of 2nd gear corners). Might go out and do FM 182, tomorrow.

Too bad the nuts did not work for you. I would next look at drilling them out. ANY decent machinist has removed many broken bolts (or worse yet taps) from critical parts. With the cases split it would be fairly easy to set on a bridgeport. He could plunge a ball endmill into the stud to create a spot for the drill to nest. Then it is a simple matter to drill the rest out. Quick and relatively cheap. EDM is a nice way to remove things that are too hard to drill like the above mentioned taps. Hit the yellow pages for machine shops and explain your situation they should guide you to the best solution.
regards
david 89 turbo cab

Splitting the case and replacing bearings and stuff is bery easy. I'm glad I did it. Studs broke off against the case is one of those "ah, well" deals. They can be drilled out and time certed if necessary. The pros know how to deal with that.

Supposedly they can burn it out with EDM without even taking the motor out of the car. That's according to Waynes' book "101 Projects". I'm assuming of course that the studs you speak of are the bottom studs.

My mistake, that was an exhaust stud in his book.

Bobby

Thanks guys. I have located two possible local sources and one nationally. Sounds like I will be splitting the engine over the next couple of days though. Superman, did you find it fairly easy to put back together? This is something that scares the dickens out of me, but too many say it is a simple task. Heck, why play with checkers when you can experience and live chess? Too much fun.

David,
I'm an amateur but I would say that, yes it is simple to reassemble but there is a lot more involved than just putting the pieces back together. I think the robustness of the engine's design shields fools (myself included) from a lot of mistakes. I'm sure a lot of motors get put back together without:
- checking the deck for flatness
- cleaning the oil galleries
- checking the layshaft backlash
- checking the oil pump for wear
- checking every oil squirter
- removing a cleaning the cam shaft spray bars
They run great (usually) and no one is the wiser but that doesn't mean it is done right. As a "beginner" every time I work on a motor I learn something and I appreciate home much I don't know. What you don't know can hurt you IMO.
I say do it but really do your research and ask questions.
-Chris