Broken exhaust manifold studs.

[@TDC]

Hey guys I have a big problem!! I had an exhaust mani stud break off in my head. So I drilled a hole and used an easy out. The worst possible thing went wrong. the easy out broke off in the stud. So basically I now have a broken stud with a broken easy out in the center. How on earth would I go about drilling out the whole stud and easy out? I'm already sure i'm just gonna have to helicoil it. What size helicoil kit would I need to get this done? What kind of drill bit would get the job done? Heres a picture of what I got.

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[@TDC]

3/32" would probably do better. The first pilot hole should be really small. A small bit will cut easier, but you have to be real careful to put just enough force on it to dig in and push dead in line with the bit. Run it slow with a little oil to cool it as you go.

Thanks alot for the help guys!!

Yes a little oil every few seconds. As soon as the oil smokes and burns off.

Thanks alot bud! Cant wait to get this over with!!

 

[H@xtGSX]

You'll be surprised at how much easier it is working it up from a little pilot hole... You will probably have it out in about 30 minutes with a gradual work up in bit size. It allows the bit to cut much more effectively, and it isn't having to try and remove the entire face worth of hardened steel, just the strip around the outside of the hole. It is easier on the bits, and will be easier on you too.

 

[aajj1987]

Well to be honest I had a stud break off on me in my head... so im using that excuse to do a head swap. went to 2 local machine shops they said they wouldn't touch it unless the head was off so bam its coming off. I hate broken studs my Camaro was a nightmare with them.

 

[@TDC]

You'll be surprised at how much easier it is working it up from a little pilot hole... You will probably have it out in about 30 minutes with a gradual work up in bit size. It allows the bit to cut much more effectively, and it isn't having to try and remove the entire face worth of hardened steel, just the strip around the outside of the hole. It is easier on the bits, and will be easier on you too.

I'm gonna try that this weekend with the stud that doesn't have the broken extractor!

 

[@TDC]

Well to be honest I had a stud break off on me in my head... so im using that excuse to do a head swap. went to 2 local machine shops they said they wouldn't touch it unless the head was off so bam its coming off. I hate broken studs my Camaro was a nightmare with them.

I'm not gonna let a stud ruin my peace of mind of having a great running dsm!

 

[@TDC]

Well guys I got the one stud drilled out and ready for the helicoil tap! I will attempt to helicoil it later tonight. Here are some pictures of the hole. I started with small cobalts and worked my way up to the 21/64. I hope it just works out with the tap later tonight. I started drilling the extractor with a small cobalt and taking it really slow until I get the carbide bit. After about an hour of slow speed drilling with oil it seems to be grinding down a bit! Hard to tell in the picture but its progress nonetheless!

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Here's the extractor stud

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[@TDC]

Well guys I bought a masonry drill bit today and decided to give it a try! It had a carbide tip. It seriously ate that hardened steel like it was nothing! I finally was able to drill out the bit and helicoil it!!! Here are some pictures!

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Test fitting my uncracked 2g mani!

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Special thanks to all of you that have helped me solve this problem! I hope my learning experience can be a guide to future DSMers that come across this problem!

 

[BogusSVO]

Good deal!! Glad it did not whoop you!

 

[@TDC]

Good deal!! Glad it did not whoop you!

Thanks a lot for all of your help! I really appreciate it! It took me a while but I'm just glad its over!

 

[H@xtGSX]

Yup, that is a pain in the ass... I have 2 to do myself now. I switched to a manifold I acid ported, and in the process of doing so, I broke one stud and stripped the other from the head... Yaaaay!

There is absolutely NO SUBSTITUTE for carbide. In this sort of work, they are a necessity, not a luxury.

 

[@TDC]

Yup, that is a pain in the ass... I have 2 to do myself now. I switched to a manifold I acid ported, and in the process of doing so, I broke one stud and stripped the other from the head... Yaaaay!

There is absolutely NO SUBSTITUTE for carbide. In this sort of work, they are a necessity, not a luxury.

Oh man! The best of luck to you! I totally agree on the carbide thing now. I used to not think it was a big difference but boy does it work. This whole process will make me think three times before I use an easy out again!

 

[H@xtGSX]

Yea, carbide is one of those things you pay for purely because IT WORKS. It is expensive, but it will save you so much time that they pay for themselves. Most guys that buy them do so because guys like us tell them to and never really find out why. You have found out why the hard way, and now when someone says they broke off a hardened bolt in something, you will pass that knowledge along.

 

[BogusSVO]

I can not tell you how many busted exhaust studs I have taken out with an EZ out. But after to break a few, you learn the "Feel" for it.

Honsetly, you had a great center hole started, but if you would have made the hole larger, go up a size or two, so about the center 2/3 of the bolt is drilled out, and got the EZ out a better bite, I would bet it would have backed out.

Also if you put a taper on the hole, you can get a wider bite with the EZ out.

 

[@TDC]

I can not tell you how many busted exhaust studs I have taken out with an EZ out. But after to break a few, you learn the "Feel" for it.

Honsetly, you had a great center hole started, but if you would have made the hole larger, go up a size or two, so about the center 2/3 of the bolt is drilled out, and got the EZ out a better bite, I would bet it would have backed out.

Also if you put a taper on the hole, you can get a wider bite with the EZ out.

I agree I think if I would of went with a bigger hole and easy out it would of backed out. I think it broke because I had only a 1/4 of an inch of the easy out actually into the stud. It was a relatively small easy out so Im sure it couldnt take the stress of me turning it since the 1/4 inch that was in the stud was fairly thin. Tapering the stud probably would have helped the easy out not break!!

 

[BogusSVO]

Live and learn right?

If you want more pratice getting broken bolts out... come down to the shop!!
Some how I think I can dig up a head or 30 with a broken stud in it!