Broke/Frozen Stud

[WyoSyclone]

Since I've had my Sy the outside stud on the passenger's side exhaust crossover flange has been broken... you can imagine the exhaust leak just having one stud holding the flange. I did a few tuning runs yesterday and decided I just didn't want to do any more until I got the stud fixed.
I've had the passenger side fenderwell out, so this morning I dropped the CAC and removed the crossover tube, which gives pretty good access to the flange. The stud had broken off at an angle and it would have been impossible to center punch, so I got a grinding stone with a radiussed head and ground the stud and manifold flange into a perfectly radiussed bowl... so, I was able to center punch and drill my first hole. I drilled up to 7/64 diameter all the way through the stud, heated the flange for about 10 minutes with my micro torch, tried the easy out, and nothing budged. I repeated 4 times and still nothing... broke the easy out but was easily able to get it out by pounding down from the top.

So, now I need the opinion of the experts.... do I,
1) Drill the hole out till I can retap the hole and just go with a 6mm stud instead of the 8?
2) Drill the hole out till I can retap for a 10mm stud?
3) keep heating and spraying with pb blaster, until I get it to budge?

Any opinions appreciated!

 

[kessler]

Re: Broke/Frozen Stud

you need to get it red hot then try pulling it. If that don't work then cut the stud down flat and drill it out with a small drill bit and gradually get bigger until you get it the same size as it was. Then just run a new thread tap through it.

 

[NecroWolf]

Re: Broke/Frozen Stud

could just drill all the way through and use a nut and bolt

 

[jwaller]

Re: Broke/Frozen Stud

could just drill all the way through and use a nut and bolt

this is a great quick fix. or simply tap it for a larger size.

 

[WyoSyclone]

Re: Broke/Frozen Stud

you need to get it red hot then try pulling it. If that don't work then cut the stud down flat and drill it out with a small drill bit and gradually get bigger until you get it the same size as it was. Then just run a new thread tap through it.

Thanks for the tip.... this stud already was broken off lower than the surface of the flange. My hole is just a bit off center which makes it a little tougher...

 

[WyoSyclone]

Re: Broke/Frozen Stud

could just drill all the way through and use a nut and bolt

Yup, I already drilled it all the way through... that's how I got the broken easy out back out. I'm thinking this may be the easiest thing to do if I can't get the manifold hot enough to release the stud.

 

[Don W.]

Re: Broke/Frozen Stud

If heating doesn't work then I would at least give some thought to trying an Heli-coil thread repair. If you have the correct drill you could drill and re-tap the hole but ya gotta keep it straight in both cases. Heli-coil may not be the best choice on an exhaust manifold. Nut and bolt may be best. If so then use a brass nut. Piece of cake next time it comes apart.

 

[WyoSyclone]

Re: Broke/Frozen Stud

Got it fixed guys... I got the new hole drilled perfectly straight but couldn't devise a way to rotate the tap that far up in there.... there may be a special tool made for that (tried a socket and that wouldn't work). So, I just used a grade 8 bolt and nut and it cinched up fine. Someday when the motor gets pulled it will be easy to tap the hole.

Thanks for all the good suggestions!

 

[Don W.]

Re: Broke/Frozen Stud

To late now but go buy yourself a set of 8pt 3/8 drive sockets. Rarely need them but when you do you'll have 'em. Perfect for your, now finished, project.:roll:

 

[WyoSyclone]

Re: Broke/Frozen Stud

To late now but go buy yourself a set of 8pt 3/8 drive sockets. Rarely need them but when you do you'll have 'em. Perfect for your, now finished, project.:roll:

Hi Don,
Yup, I've got those but they don't fit the 8mm tap that comes with the Kobalt taps from Lowes...ahh, that's my problem - buying taps from Lowes!

 

[TYTILIDIE]

Re: Broke/Frozen Stud

I used a nut and bolt on a friends truck a couple years back. I figure, why put yourself in the position for it to do this again?

 

[WyoSyclone]

Re: Broke/Frozen Stud

I used a nut and bolt on a friends truck a couple years back. I figure, why put yourself in the position for it to do this again?

Yup, I agree.. if the darn thing breaks, just replace it rather that having to go through all this crap with the broken off studs!