Header studs broke

[blackhawk2k7]

so for a while now i was dealing with the fact/problem that my left-most header stud snapped off flush with the exhaust manifold headers, now i tried to remove my headers to access it and E-Z out the broken stud, but low and behold when i went to loosen the neighboring stud it snapped same spot as well, what can i do? where would i go to repair this? a machine shop? a mechanic? carpenter? im at a loss. but i plan on getting the evo III high flow headers and ARP studs, so i WONT ever have this problem again. where can i take her to deal with my problem?

 

[junk240sx]

There are a few ways you can get it done, using stud extractors or welding a washer/nut to it. I've seen the welding method used and it's very quick. If you can rent a welder, might be worth trying. Don't have to be a great welder. Look up videos on youtube on how they do it. Basically you get a washer that's got a hole slightly smaller than the stud, and weld in the hole so the washer is welded only to the stud. Then you weld on a bolt on top of the washer. If the weld is good, you can then unscrew the stud from the bolt.

 

[blackhawk2k7]

cool idea, funny thing, i just graduated job corps for their welding program, so this will be a true test... so washer welded to stud, then nut welded to washer... with pleanty of pb blaster

 

[BogusSVO]

the weld method will work only if a thread or two is above the casting.

arp or not, I will still bet you will break headder studs if you do not install a lower support on the turbo

 

[90gst_sean]

When I first rebuilt my engine I had a couple of broken ex. manifold studs and used two methods to fix them.

1- I used an easy out, on the easy one, and this worked great.

2 - I used my local machine shop to extract the second stud because it was extra hard and I drilled my extractor hole a little off center.

If you're going to take the head off for any other reason or if taking the cylinder head off is no big issue to you I suggests letting the machine shop remove it for you. If you're having the shop do other work at the time you have them remove the stud they may not even charge you for the job, as was the case for me.

After removing both studs, I installed all new ex. manifold stud from SBR and haven't had a problem sense and it's been about three years / 20,000 miles.

P.S. I've been running no upper down-pipe support mount ever sense I installed my after-market down-pipe about 2.5 years ago.

I'm curious how people are still using the down-pipe support after moving to an after-market DP like Megan Racing or the like. A poster above mentioned breaking manifold studs due to not having a turbo support...are we talking about the same support? Pictures would be great.

 

[blackhawk2k7]

thanks for the advice, ill end up going to a machine shop, i need something small 'else' done, ill ask if they could throw it in, thanks

 

[steve]

Plan on replacing all of them.
If they don't break removing them, they usually break putting the manifold back on.