Broken Exhaust stud repair

Broken exhaust stud repair.



I had a cylinder head come to the shop, it had a bad drilled exhaust stud.
Whoever tried to remove the broken stud before, did not do the best of jobs.
Part of the old stud was still in the hole. Along with part of an EZ out.

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I took a die grinder with a carbide burr and ground out the stud and EZ out.
I was left with this for a hole., I knew a simple Heli-coil would not fix it.

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So I made a bushing to repair it.

The head casting was drilled and tapped for a ½ x 13.

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Next I installed a set screw. You could also use the threaded part of a bolt.

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Use “Green locktite”

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After about an hour, the locktite is set up. Drill the set screw .2660, then tap for 8mm x 1.25

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Next fit the stud.

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The customer should not have any exhaust alignment issues of the exhaust manifold now.

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