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

["therealdmcvegas" <dmcvegas@xxxxxxx>]

Haven't had anything THAT extreme happen, but I have had a very
simular situation on my car. Except that I broke off a stud holding in
the water bypass flange in the head, with a broken extractor in it too.

Get a Dremel, with a flexable pencil tip attachment. Bit # 9910,
Tungsten Carbide Cutter. Use this to grind out the remainder of the
bolt. I't STRONG bit, as I was even able to use it to extract a broken
extractor in the bolt.

It's small enough to fit in the hole, and grind the bolt out, without
you hitting the head. And you'll know what you're hitting by the
sound. Grinding aluminium sounds like a dull thumping. But when you
hit that steel bolts, the sound will be a high-pitched grinding, with
sparks flying everywhere. Grind/drill enough out of the center, and
you should be able to shatter the rest of the bolt out of the hole.

Once the bolt is out, chase/retap the threads in the hole, and you're
good to go!

-Robert



--- In DMCForum@xxxxxxxxxxxxxxx, "Digital Devices" <ken@xxxx> wrote:
> 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
> 
>  
> 
>  
> 
> 
> 
> [Non-text portions of this message have been removed]

---

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