Anyone ever break a head stud?, Looking for ideas, tools success stories, horror stories, what cha got Options

[rick 918-S]

I'm building a 928 hybrid engine which is comprised of a 5.0L 32 valve short block with 16 valve euro spec "S" heads, spyder and CIS from the 4.7L "S" engine.

I stole some time from my busy work schedule to prep my 928 block for the machine shop. The head studs need to be removed for the boring process.

Now I've pulled studs before without incedent. But as Murphy would have it, this time I broke one of the studs flush at the start of the threads.

So I have the threaded section ( 1 1/4"long ) hardened head bolt stuck in the block. Normally this wouldn't be a problem, but the stud is free standing in a 3 1/2" deep hole in the block!

Here's a crude drawing of the problem I'm faced with.



Here's the stud.



Here's the stark reality of the stud in and out of the block. The stud slides down a 3 1/2" deep hole in the block before it starts to thread in.




I'm going to make a drill collet as a guide for a pilot bit. The problem is I need a long, reverse twist drill bit.

Most drill bits are approx 5" long. the hole is 3 1/2", the threaded section is 1 1/4" for a total of 4 3/4". See the problem?

Then, what the #$!! do you drill a hardened bolt with?

Anyone know of a good tool source? This is beyond most Mac and Snap on stuff I would think.

[r_towle]

Have you called 928 international??? Maybe they have a cure for this???
Or Pevec (SP) the guy who hot rods these motors???

I am sure someone has dealt with this in the 928 community before.

Rich

[rick 918-S]

Have you called 928 international??? Maybe they have a cure for this???
Or Pevec (SP) the guy who hot rods these motors???

I am sure someone has dealt with this in the 928 community before.

Rich

I posted this problem over on the list where the 928 Int guys hang out, and the bird. The consenses seems to be if the stud breaks in the block it's junk. Granted, the guys in the know on the list seem to be luke warm when anyone asked a real question.... The guys on the bird are much more helpful but there are fewer of them. Not like this place.