2G Broken Exhaust bolt in Head

[Type1DSMr]

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?

 

[BogusSVO]

http://www.dsmtuners.com/threads/broken-exhaust-stud-repair.457207/

 

[Type1DSMr]

Ok looks like I need to drill out remaining bolt left in there and use a helicoil kit 5546-8. Would a screw extractor kit work or should I just use a cobalt bit to drill out?

 

[BogusSVO]

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

 

[Type1DSMr]

Ok the helicoil kit calls for a 21/64 drill bit. As long as I remove the rad and fans, I should be able to do this while the head is still in the car correct? Thanks

 

[Type1DSMr]

Also a helpful member told me to drill in 40mm or 1 1/2 inch into the head.

 

[gofast63]

I had mine break on me last week. I welded a nut to it and got it loose after the third time welding it. Lol.

 

[Type1DSMr]

Nice wish I had that option but the previous owner already tried to drill through it and did a bad job. But at least all the other studs came out.

 

[BogusSVO]

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.

 

[Archer Fabrications]

If you have a welder or know someone that can (tig) weld a bolt to the broken stud and get it out. Preferably a smaller bolt.

 

[Type1DSMr]

So I can't find a cobalt 21/64 drill bit locally, would a titanium bit work?

 

[Lou98GSX]

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 .

 

[Archer Fabrications]

So I can't find a cobalt 21/64 drill bit locally, would a titanium bit work?

Are you sure cobalt isnt the brand that was recommended, i wouldnt think material matters, the studs are just steel with zinc coating.

 

[Type1DSMr]

No cobalt drill bits are the material in the bit. Used for drilling hardened steel and titanium bits are harder but not able to be resharpen. I thought the studs are a 10.9 grade.

 

[Type1DSMr]

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!

 

[Maes]

Good job looks good

 

[Archer Fabrications]

Thats funny it's the same stud hole on my soare motor that someone had to drill and tap, that one above #4 is the same size as the two outer big studs

 

[Type1DSMr]

I guess that one just loves break. I got lucky as its the regular size and didn't have to use a bigger stud. Tell you what tho I was nervous as all hell drilling into the head.

 

[Type1DSMr]

Oh thanks urbansmoker for the tip on anti seize.