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Recently I realized that I had 2 exhaust studs snapped off. Oh well, a little noise... then the noise became a bit worse and SWMBO indicated an imbalance in trade was looming - so I decided to deal with it.
Local indie suggested about $500 to replace the studs. Hm, well I'm not about to drop $500 without a little saturday afternoon tinkering, so:
I borrowed my brother's screw extractor set. Made by MAC I believe.
It contained:
1. Various Left hand twist drill bits
2. Various sleeves of various external and internal diameters
3. Various hardened splined shafts of various diameters. Note - non-tapered.
4. Various hex "nuts" with splined insides to match the shafts
I removed the electric fan and rad shroud. Not too hard.
This gave sufficient room to actually put my old Makita drill in place and drill a hole right down the centre of the stud. How did I do this?
By placing one of those sleeves in the hole in the exhaust manifold that fit closest and had the smallest hole in the centre. This allowed me to put a tiny drill in and the sleeve kept it aimed correctly.
With this pilot hole, I was able to put in a larger (inside dia.) sleeve and drill a larger hole.
Then, I chose a splined shaft of approximately the right diameter and tapped it in. It went all the way through the stud and out the other end. Then I place one of the hex "nuts" onto the shaft (obviously the one with the splined inside matching the shaft) and backed the broken stud right out!
Key observations:
1. The splined shaft didn't have to match exactly. Because it contacts the inside of the stud for the whole length, it had plenty of grip.
2. Broken studs aren't jammed into their holes. Often just drilling with a left hand twist drill will back a stud out.
3. The sleeves worked! When the studs were out, the hole was right down the centre!
4. I bought my brother a 2-4 of beer and was about $475 ahead of the game.
posted by 216.75.190...
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