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Removing broken exhaust studs

My experience with removing broken exhaust studs:

I doubt anyone has broken 9 studs while removing the heat exchangers.
I managed to do that.

While i manged to drill 7 out with titanium and cobalt drill bits, the two on cylinder 6 were different.
Broke few drill bits and they were not even scratched.

After some research i bought rescue bit which chewed up the studs like there is no tomorrow. If in similar situation, i highly recommend not wasting your time and money on something else and go with this tool. It is almost unbelievable how good this tool is.

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Old 01-12-2018, 06:45 AM
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What are the specs on that bit so I can search for it on amazon? TIA
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Old 01-12-2018, 06:55 AM
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There are few sizes available.

Here is the link:
https://the-original-rescue-bit.myshopify.com/

It is also good for removing broken bolt extractors inside the stud, NOT A FUN SITUATION.
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Old 01-12-2018, 07:00 AM
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Bit

Please provide more details on the bit manufacturer - Thanks
Old 01-12-2018, 07:00 AM
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Quote:
Originally Posted by kavadarci View Post
Wonderful tip, thanks! Love this forum, learn something new every day.
Watched the video on their website drilling out a hardened screw extractor, awesome! Which size bit did you buy for the exhaust studs?
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Old 01-12-2018, 07:30 AM
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I got the 1/8 but i think the bigger would do just fine.
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Old 01-12-2018, 08:01 AM
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That's definitely a nice tool to add to the drill & grind collection. Thanks for sharing!

But I have to ask, why did you keep breaking the studs? It's been posted on the forum so many times that the studs/nuts need to be heated super red hot to get the nuts off w/out breaking the studs.

This bit is for sure a really nice way to get us out of a pickle if something like an extractor is broken. But does it really help save the hole? I suppose if you're really careful and patient you can open up the hole with the bit and try to salvage the threads. But I feel like it's really hard to be precise with that approach and some threads are going to get damaged.

The best solution i've seen is the drill guide that indexes off of the exhaust port. It allows you to precisely drill the center of the stud and pick out the remaining threads. So after clearing out the broken extractor with the bit, the drill guide does a great job of removing the rest of the broken stud

https://www.stomskiracing.com/products/exhaust-head-stud-repair-kit

But I totally recognize that tool is quite expensive. A lot of folks around here are willing to lend out their tools so all we have to do is ask here on the technical forum or post a want-to-borrow thread on the engine rebuild forum or the classified ads
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Old 01-12-2018, 09:02 AM
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Quote:
Originally Posted by KTL View Post
That's definitely a nice tool to add to the drill & grind collection. Thanks for sharing!

But I have to ask, why did you keep breaking the studs? It's been posted on the forum so many times that the studs/nuts need to be heated super red hot to get the nuts off w/out breaking the studs.

This bit is for sure a really nice way to get us out of a pickle if something like an extractor is broken. But does it really help save the hole? I suppose if you're really careful and patient you can open up the hole with the bit and try to salvage the threads. But I feel like it's really hard to be precise with that approach and some threads are going to get damaged.

The best solution i've seen is the drill guide that indexes off of the exhaust port. It allows you to precisely drill the center of the stud and pick out the remaining threads. So after clearing out the broken extractor with the bit, the drill guide does a great job of removing the rest of the broken stud

https://www.stomskiracing.com/products/exhaust-head-stud-repair-kit

But I totally recognize that tool is quite expensive. A lot of folks around here are willing to lend out their tools so all we have to do is ask here on the technical forum or post a want-to-borrow thread on the engine rebuild forum or the classified ads

Excellent question.
I did heat mine red hot, followed every single instruction, watched so many videos.
Mine were rusted in the middle so much that slightest turn broke them.
Once they broke, the 10mm that was sticking out i tried to remove with stud remove and broke again. The studs felt "welded" like.

I did buy the stomski racing drill guide and used my heat exchanger flange and that's how i drilled the rest of the studs going from smallest to highest drill bit and finally just tap tracing the thread. none of the threads were damaged and all the studs are solidly in place (i did put anti seize for the next happy guy).

These last two were different as i said, not sure why but the same drill bits that were going into the other studs fine, couldn't even scratch the surface.

Take a look at my "custom" tool


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Old 01-12-2018, 09:19 AM
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NICE!!!



Job well done and thanks again for sharing that Rescue Bit. I'm sure that bit will save my butt at some point in the future!

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Old 01-12-2018, 09:28 AM
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Thanks for sharing. It's a daunting circumstance and many people have either been there or will go there someday. Awesome it's on it's way back.

Old 01-12-2018, 10:46 AM
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i have one of those bits too...it works when nothing else works!
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Old 01-12-2018, 10:51 AM
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Mine were all rusted in the middle to and just snapped rite off. Hogged mine out to 10mm and used allens this time around. Can tighten the crap out of them now.
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Old 01-12-2018, 11:08 AM
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Mine were all rusted in the middle to and just snapped rite off. Hogged mine out to 10mm and used allens this time around. Can tighten the crap out of them now.
This too seems like a smart move. A very smart move and one I would consider.
Old 01-12-2018, 11:12 AM
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Dremel also makes a little carbide bit like that. It works surprisingly well and is waaaay cheaper.

Dremel 9903 is what I have used.
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Last edited by gtc; 01-12-2018 at 11:18 AM..
Old 01-12-2018, 11:13 AM
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I think Dremel with carbide might have worked on the other studs it again did nothing on these two. Not sure again why.

Also Allen bolts is a great idea I might do that.
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Old 01-13-2018, 05:33 AM
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