HELP broken exhaust bolts

[Bill99]

I broke 2 exhaust bolts when removing the headers and want to know whether anyone would have a Stromski Racing Exhaust Bolt Repair Kit that they would rent or loan? I will of course pay shipping, etc. I hate to spend $300 for a one time use tool.

Please help.

Bill

[JmanB]

Originally Posted by Bill99

I broke 2 exhaust bolts when removing the headers and want to know whether anyone would have a Stromski Racing Exhaust Bolt Repair Kit that they would rent or loan? I will of course pay shipping, etc. I hate to spend $300 for a one time use tool.

Please help.

Bill

Where are you located?? I have one.

[Trackrash]

Some skillful use of a hand drill works. Start with a small bit, make sure you are in the center of the stud and square. Work up in drill size until just the threads are left in the head. You can use a pick to get those out. Of course if the drill wanders into the aluminum, you are going to have a larger problem.

[mepstein]

That’s why the kit is so good. Less chance of error.

[sugarwood]

Originally Posted by Bill99

I hate to spend $300 for a one time use tool.

Please help.

Bill

Spend the $300 to support a small business that is getting you out of your jam.
If everyone shared the tool, the tool would not exist in the first place.

[Trackrash]

No question the tool is worth while. However if you have a wire feed welder you might try to weld a nut on the broken stud. Worth a shot.

[Bill99]

A lot of different tools but no welder. I hear that works pretty well. I tried an extractor on one of the bolts but it just broke again even with the engine.

[pkabush]

Originally Posted by Bill99

A lot of different tools but no welder. I hear that works pretty well. I tried an extractor on one of the bolts but it just broke again even with the engine.

This happened to me on one of many broken studs. You’ll definitely want the jig.
Stud extractors are made with hardened steel. Makes it almost impossible to stay centered if you’re trying to freehand it.
Good luck.

[Bill99]

I agree with what you say about the stud extractors. I believe that this approach has too many possible failure points. That is why I want the tool made specifically for this issue and that has been proven to work.

[john walker's workshop]

Buy the tool and sell it when you're done.

[Showdown]

A $300 guarantee that you don’t make a $1000 mistake seems like a good investment.

[boyt911sc]

Originally Posted by Showdown

A $300 guarantee that you don’t make a $1000 mistake seems like a good investment.

Julian,

I completely agree with your statement. More than 25 years ago, I did my first 911 engine rebuild replacing the broken exhaust studs. I didn’t recall if it was available at that time and did my best. It was Ok but not comparable to today’s results using the jig.

I bought a used exhaust jig later about 15 years ago and been very satisfied with the results. I still have my first motor but it won’t accept a set of heat exchangers or headers without modifying the holes on the flanges. Imagine filing the holes of SSI headers for hours just just to be able to mount them.

Avoid replacing or repairing exhaust studs without using the jig. Or you might regret. You maybe lucky but your chances of getting them aligned is heavily against you. This is probably one of the best tools a DIYer should have in his tool box. Borrow or buy and re-sell at a discount.

Tony

[Dpmulvan]

If you don’t get the hole perfectly centered it’s over.

[Bill99]

I understand all the issues and am just trying to keep the cost down. Eventually if I can't get any help by renting the tool I will buy one. There is no way that I will try to do this particular job any other way.

[mepstein]

If you need the tool now and are going to keep your car or stay into Porsche for a while, it’s worth just buying the tool and keeping it in your toolbox so the next time it happens, it’s just an annoyance, not an emergency. If you decide not to keep it, it’s easy to sell for 2/3’s what you paid.

Full disclosure, the shop where I used to work has all of Stephen’s tools, they are really well made and do the job they were designed for. He’s a smart guy.

[slow&rusty]

Originally Posted by mepstein

If you need the tool now and are going to keep your car or stay into Porsche for a while, it’s worth just buying the tool and keeping it in your toolbox so the next time it happens, it’s just an annoyance, not an emergency. If you decide not to keep it, it’s easy to sell for 2/3’s what you paid.

Full disclosure, the shop where I used to work has all of Stephen’s tools, they are really well made and do the job they were designed for. He’s a smart guy.

I agree 100%..well said

I bought the Stomski tool and it saved my backside a few years ago, yes it was a lot of money at first but worked perfectly and I've used it once and plan to keep it.

Rolls Royce used to say something along these lines "Enjoyment will outlive the initial purchase price shock....exponentially"

[don gilbert]

All is not lost on a little mistake. Someone really messed mine up on an 82 3.0, plenty of room to go 10mm and use hard allen head bolts. Can tighten the crap out of them.

[slow&rusty]

In Action!

[Bill99]

What tool is this? I was looking for the SR67 kit which has the full fixture.

[Bill99]

Oh I see that is the SR65 kit.