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2G Broken Exhaust bolt in Head

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Type1DSMr

Proven Member
1,114
149
Jul 27, 2014
Jasper, Indiana
Ok so again this was like this before i got the car. Po broke one of the exhaust studs in the head and did a horrible job trying to fix it. What can I do to fix this? Looks like they tried to drill it out but with a big bit because all of the threads areally gone. Any suggestions would be great that I can do myself as I can't take it anywhere. I want to be able to fix it correctly but if I can't, what would be a way to seal without leaks?
 

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As bad as it is mangled I would skip the ez out, and just drill it out.

2 maybe 3 drill bits stepping up in size
 
Normally there is a touch of space behind the stud, you will know when you have drilled thu the stud.

Either the drill will "drop" a bit or you will be seeing aluminum flake in the drill chips, either way you will know you have gone far enough.
 
the best way is with a welder but if you don't have one then the other option is to drill and tap . you can try to use an easy out but if you feel it's not going to come out don't force it to the point where it's going to break the easy out . if you drill i would measure the depth of the other holes and put some tape on the drill so you don't go past that point .
 
Well finally track down a cobalt 21/64 drill bit from napa and it worked awesome. Had no problem drilling out old bolt and I used two helicoil threads. For my first time I think it came out pretty good especially with the lack of room in the engine bay. Thanks for all the help everyone!
 

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