 Exhaust stud woes, What's the next step? |
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| saigon71 |
 Jan 24 2015, 11:39 AM
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Advanced Member  Group: Members Posts: 2,006 Joined: 1-June 09 From: Dillsburg, PA Member No.: 10,428 Region Association: MidAtlantic Region 
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Nothing is ever easy on these cars...
My heat exhangers got some oil in them from the bad oil cooler seals, so I decided to pull them for a good cleaning. One exhaust nut was really difficult to remove. Once I finally got it off, I saw that the threads were galled. Ordered some new exhaust studs. Went to work removing the old one after researching 914 world. Heated stud boss with MAP torch & sprayed a bunch of PB blaster. Welded a nut on the end...nut kept breaking loose without budging the stud, removing small portions off the top of the stud during the six attempts. Then welded a bar to the remainder of the stud and used an adjustable wrench for leverage. Heat & PB Blaster, working it a little at a time, back & forth. It finally broke free. Reheat & apply more PB. On about the 5th cycle, the stud broke off below the level of the head. Engine is in the car & I'd like to keep it that way. What are my best options for getting this thing out now...and installing a new stud? I've had horrible luck with EZ-outs on other applications. Thanks!        |
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| 913B |
Oct 2 2015, 02:43 PM
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#2
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Senior Member Group: Members Posts: 853 Joined: 25-April 05 From: South Bay/SoCal Member No.: 3,983 Region Association: None |
Dang you the MAN, I like your persistence and not give up.
I am subscribing to this thread for future reference. BTW, how thick was that drill jig have to be ? Drill bits, was there special drill bits you use/recommend for this job ? I take it harbor freight ones would NOT do. Great job ! (IMG:style_emoticons/default/first.gif) (IMG:style_emoticons/default/first.gif) (IMG:style_emoticons/default/first.gif) Ted |
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| saigon71 |
Oct 3 2015, 04:22 PM
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#3
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Advanced Member Group: Members Posts: 2,006 Joined: 1-June 09 From: Dillsburg, PA Member No.: 10,428 Region Association: MidAtlantic Region
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QUOTE(porsche913b_sp @ Oct 2 2015, 04:43 PM)  Dang you the MAN, I like your persistence and not give up. I am subscribing to this thread for future reference. BTW, how thick was that drill jig have to be ? Drill bits, was there special drill bits you use/recommend for this job ? I take it harbor freight ones would NOT do. Great job ! (IMG:style_emoticons/default/first.gif) (IMG:style_emoticons/default/first.gif) (IMG:style_emoticons/default/first.gif) Ted Thanks Ted. Necessity is the mother of invention. (IMG:style_emoticons/default/dry.gif) My drill jigs are about 3/8" thick. I used a set of Dewalt pilot point drill bits (set was about $20), purchased at Lowes and plenty of lube. |
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Posts in this topic
saigon71 Exhaust stud woes Jan 24 2015, 11:39 AM
pilothyer I know this is not what you want to hear, but sinc... Jan 24 2015, 11:49 AM Mark Henry Really hard to do in car.
What you did there is s... Jan 24 2015, 12:03 PM veekry9
Nothing is ever easy on these cars...
....It fin... Jan 24 2015, 01:25 PM larryM . your question updated
you should be able to get... Jan 25 2015, 01:22 PM stugray It can be done as mentioned above, but if you are ... Jan 25 2015, 11:13 PM JamesM Pull the engine now, it will save you in the long ... Jan 26 2015, 04:58 PM
larryM X2
assuming you have plenty of money, & can ... Jan 27 2015, 10:35 PM Mueller I botched an attempt at drilling out an exhaust st... Jan 28 2015, 09:20 AM 9146986 You'll get closer to hitting the center of the... Jan 28 2015, 09:37 PM relentless The stud is broken off below the level of the head... Jan 29 2015, 04:05 PM 9146986 I didn't mean to sound insulting Saigon, I jus... Jan 29 2015, 09:48 PM stugray
A vintage piece of equipment that really works go... Jan 30 2015, 12:05 AM saigon71 Thanks for all the advice and suggestions – I gr... Jan 31 2015, 05:06 PM saigon71 Made three different fixtures so I could step dril... Jan 31 2015, 05:31 PM type47 Go Bob, go! :trophy: Jan 31 2015, 05:40 PM saigon71 I am very happy to report that it worked well. Us... Jan 31 2015, 05:47 PM mepstein Wow! You knocked it out of the park. Congrats... Jan 31 2015, 05:54 PM saigon71 Glad to have this project done! I’m going t... Jan 31 2015, 05:59 PM Cap'n Krusty "New" exhaust nuts? Good luck finding t... Jan 31 2015, 07:03 PM mepstein
"New" exhaust nuts? Good luck finding ... Jan 31 2015, 07:11 PM Bartlett 914
"New" exhaust nuts? Good luck finding ... Feb 1 2015, 12:21 PM stugray
Would you mind showing a pic of the proper nuts? ... Feb 1 2015, 01:49 PM 914Mike I've used brass nuts, never had one get stuck ... Jan 31 2015, 11:22 PM relentless Nice job! I picked up some 8mm copper exhaust... Feb 1 2015, 01:57 PM pilothyer These should work Helicoil Flange Nuts Feb 1 2015, 02:26 PM Harpo
These should work Helicoil Flange Nuts
This sup... Oct 1 2015, 06:15 PM ClayPerrine I use a Mercedes Benz exhaust manifold nut.
Merce... Feb 1 2015, 06:25 PM ThePaintedMan This is one of the most well-thought out and brigh... Feb 2 2015, 08:00 AM mepstein Stomski makes a tool in a kit with all different a... Oct 1 2015, 04:06 PM saigon71
Stomski makes a tool in a kit with all different ... Oct 3 2015, 04:17 PM wndsnd I am impressed. It sucks working on your back wit... Oct 1 2015, 07:39 PM mepstein I would think so since there are many different si... Oct 3 2015, 04:25 PM ctc911ctc I started replacing all of my studs with the engin... Apr 7 2020, 12:26 PM Bleyseng
I started replacing all of my studs with the engi... Apr 7 2020, 03:42 PM |
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