[DML] Re: Broken Exhaust Manifold Stud

["dmc_5180" <dmc_5180@xxxxxxxxx>]

Craig,

This is a bummer,  When I bought my car years ago it had the very 
forward most studs broken off flush on both sides of the engine.
 Ofcoarse because of the frame being in the way I had to be creative.  

Since I was replacing the all the studs and using the high quality one
piece gasket. I had the hardware I needed to make things work.

I used a small piece of 1/2 inch think steel bar stock I happened to
have at my work to create a drilling jig.   I used the new gasket as a drill
 template and marked out all four holes.  Then drilled the the holes 
the same size as the drill bit required for my E-Z out. After that was
done, I then drilled two opposite diaginal holes out to 7mm. I installed  
two of my new studs in the unused holes in the head and bolted the 
dril jig to the head. Because, my studs where in the worst location.
I had to purchase a 90 degree reversible air drill and bought a lefthand
drill bit. I probably didn't need the bit, but it worked.  The jig 
guaranteed my drill was centered and true. After the stud was drilled
I tapped in the E-Z out and remarkibly the studs came out quite easily
Much to my surprise.

The diligence I took to do this job paid off. Big time.

Hope your studs aren't In that bad of a location. But the principles are 
still the same.

Good luck

Dennis


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