Need Advise on fixing broken exhaust mani bolts

[BOBS90TURBO]

I just bought a HKS hi power exhaust and a 2g exhaust manifold, the HKS is great, but when I was taking off the old 1g manifold I broke 3 bolts off flush with the head, in other words there is no room to get ahold of the broken bolts...I tried to use a reverse bolt puller and it broke off inside the broken stud and now I can not drill out the bolt because the broken puller piece is so hard I keep breaking drill bits.

Any advise on how to get the broken studs out....What are the strongest bits made????? I have been useing the high speeds from Craftsman.
Thanks

 

[kristmen]

Um its really not that hard. You buy an easy out, drill the studs and insert it and extract the broken stud.

Once you get it out drill and tap your head for 10mm studs. Those ####ers are beefy and dont break easy and you can crack the bolts a lil bit tigher without worry of breakage.

Can always take it to a machine shop too.

 

[BitAddict]

Drill the holes and try using a "Screw Extracting" set from sears. normal easyouts wouldnt work for me but that set worked 10x better. good luck!

 

[92GSXman]

Buy some nice carbide bits- they are expensive but they last alot longer. Plus you will need one to drill out that broken extractor.

 

[kristmen]

O shit I didnt see that part about the extractor breaking... I was sorta in a hurry.

Damn....

I had one of them ####ers break and I couldnt drill it out for the life of me. I took it to the machine shop and they wouldnt even touch it.

Its ok to run a manifold with a couple bolts missing though. So you might just wanna call the one with the broken extracter a lost cause and try to fix all the rest. Hell I'm missing 2 studs and nothings leaking on my ride....

Just get one of them 4 layer copper or steal gaskets and snug up the rest of the studs. Make sure you use 10mm by 1.25 on atleast the outside edges of the manifold and you will be fine even if you cant get that extractor and stud out.

 

[BOBS90TURBO]

I have wore out 10 drill bits now trying to drill into the broken extractor, I think I am going to give up and take your advise and try to live without the 2 studs with the extractors in them... Thanks For the Help!!

 

[kristmen]

As long as both are not end studs on the same end, you should be ok if your manfolds not warped.

Take it in and have it checked, get a 4 layer gasket and your should be ok.

If you can put those 10mm by 1.25 studs atlease in each end then you can crank down on the nuts a bit to help make sure you dont get any leaks.

Like I said I'm missing 2 studs and I dont have any leaks that I can hear or see.

 

[foreverinvayne]

I don't know about any of those guys, but me and my dad were able to drill through the extractors with the carbide bits. i think we had 2 or 3 studs with the broken easyouts in em. got all four out and replaced em. he did most of the work since he's a mechanic. I can talk to him about it and tell you EXACTLY what he did tomorrow. once he figured out how to do one, he had the other 3 done in a matter of a half hour to an hour or so it seemed.

 

[Defiant]

Very time-consuming, but you may be able to grind the extractor bits with a Dremel. It'll take a lot of grinders, but life's for learning. You might try a Dremel carbide cutting bit, I don't know if it'll get through the extractor or not.

The other method would be to weld something onto the broken stud and use it to extract with.

 

[SrKegler]

Easiest way is get a sharp punch and a Big F'n hammer. Smack the EZ out a few times and it will shatter. Use a magnetic probe to pull the pieces out of the bolt hole.

Another solution is just use a MIG welder and weld a bolt on to the piece that's stuck in the head. Usually the heat from the MIG will be enough to loosen it up.

 

[BOBS90TURBO]

Thank You so much for all this advise,,,,I was about to give up,,,well off to do me some drilling