RE: [DMCForum] Broken Exhaust Manifold Stud NIGHTMARE! Please Help ...

[Travis Goodwin <tgoodwin@xxxxxxxxxxxx>]

Let me just say from experience. Yes, you can pierce the water jacket. If
you want to try to drill them out, mark your drill bit so you can be sure
not go beyond that distance. It's most likely that you will have to drill
and tap, but depending on where the studs are, that could be a huge pain in
the ass.

I would recommend taking the head off. It's really not that difficult to do,
it just takes some planning.

I drilled right into the jacket and had to take it off to get it repaired.
It gave me a chance to get in and really clean the engine up and replace all
the vacuum hoses and water hoses.

-----Original Message-----
From: Digital Devices [mailto:ken@xxxxxxxxxxxxxxxxxxx] 
Sent: Thursday, May 26, 2005 10:19 AM
To: dmcforum@xxxxxxxxxxxxxxx
Subject: [DMCForum] Broken Exhaust Manifold Stud NIGHTMARE! Please Help ...

Hello all ... long time since I posted, but I am back and back with a big
headache!

 

Upon removing my factory exhaust system, in preparation for my new setup, 3
studs decided to break on me.

 

They broke off about ¼ " or less INTO the head (so there is NOTHING sticking
out to grab onto)

 

To add to the headache, they are the studs that are located in the hard to
reach area right at the front of the engine towards the front of the car

 

(which means that there is the part of the frame obstructing from making a
"roomy" space to remove them)

 

we have tried to drill out one, without success (it did not BUDGE at all) 

 

I am fully aware that if things are messed up here, the engine could be
compromised, simply by drilling too far (and puncturing a water pocket)

 

 

HEEEEEELLLP!

 

Suggestions? Secrets? Miracles?

 

Any and All help is greatly appreciated!

 

Thank you

Ken

005541

 

 



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