Broke a turbo stud, weld another bolt onto it? Water leaking?

[meliketoball]

Broke a turbo stud, weld another bolt onto it? It broke flush with the ex. mani.

I was thinking about welding another bolt onto the broken one then threading it out the way it should come out or if that doesn't work, drill and tap threads into the broken bolt and jb weld another bolt into the broken one to take it out.

Any other ideas?


The reason I was taking off my ex. manifold is because I have a water leak. It seems to travel down from (I don't know what it really is.) a metal heater hose behind the ex. manifold down to one of the turbo water hoses. I popped a water hose for my turbo and overheated. and after, it started leaking water after I changed all water hoses, thermostat, etc.

Do those things crack when it overheats?

 

[romeen]

If you do take the turbo off you can also consider taking it to a machine shop for removal of bolt. It will probably cost about $20 but can save a lot of hassle. Those bolts are very hard making drilling them difficult.QUOTE]

I warned you.

Yes, you will probably want a tungsten carbide drill bit. Otherwise, not only will it take forever to drill the bolts but the bit may end up breaking off inside of one as well thus compounding the problem. Any drill bit can break so be careful as you get deeper into the bolt.

 

[vernvision]

A cobalt/carbide tungsten bit usually runs about $15 dollars each for the smallest to over $50 at 5/8 or bigger. These are for drilling very hard metals. They are expensive usually at the hardware store they are under lock and key. The titanium coated bits are junk. I have been working with metals for a long time and the only bit I use for steel iron etc is a hardened cobalt bit. It will cut through that stuff like butter but if you are using a hand drill you need one that turns the bit slowly so that it doesen't get to hot. You will need thread cutting oil as well to keep the bit cool. Too much speed and you create friction and heat which removes the carbon from the bit which makes it soft and it won't cut. I spent $175 on a set of cobalt bits which was at wholesale so you need to get the right bit. I aggree with the others though I would pull it all off unless I was not going to keep the car. If you do one thing half ass it will come back and haunt you later ask any DSMer about that.

 

[Daveed]

I was able to undo enough stuff to get the exhaust manifold pulled back from the head and slid up the stud. With it off you have about 3 inches of the broken stud to use a stud remover on. I bought a nice BIG one from sears and with some PB plaster and some heat from a propane torch got it out (oh yah, the 1/2" breaker bar helped too).

I was able to undo a number of things (including turbo hoses, the clamp holding the exhaust to the block, the turbo oil feed line at the head, all the bolts and studs on the exhaust manifold...which usually means removal of the PS pump) to get the manifold and turbo pulled back from the head.

PS If the stud broke off at the top then theres a good chance of breaking an easy out on it as well. Lots of heat and penetrating oils may work but I'd recommend getting that exhaust manifold off one way or another so you can really get at the stud. Be careful not to break it off in the turbo though (use heat and oils again).

 

[meliketoball]

I was able to undo enough stuff to get the exhaust manifold pulled back from the head and slid up the stud. With it off you have about 3 inches of the broken stud to use a stud remover on. I bought a nice BIG one from sears and with some PB plaster and some heat from a propane torch got it out (oh yah, the 1/2" breaker bar helped too).

I was able to undo a number of things (including turbo hoses, the clamp holding the exhaust to the block, the turbo oil feed line at the head, all the bolts and studs on the exhaust manifold...which usually means removal of the PS pump) to get the manifold and turbo pulled back from the head.

PS If the stud broke off at the top then theres a good chance of breaking an easy out on it as well. Lots of heat and penetrating oils may work but I'd recommend getting that exhaust manifold off one way or another so you can really get at the stud. Be careful not to break it off in the turbo though (use heat and oils again).

I think I am going to try to pull the exhaust manifold off then with it off I can work at that broken stud. I tried drilling into it.. oh man, it was so hard.