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Well I went to work on the Aero.....finally. I removed the A/C compressor and bracket and the oil cooler so I had room to work. I used a mirror to look at the broken stud. It was broke off below the surface of the head and was still pretty centered in the hole in the exhaust manifold. The break was spiral shaped, which is pretty common. Since it was broken well below the head surface, you couldn't use a large 7/16" bit to start a centering divot. I looked around the garage and found my set of centering punches. They were exactly what I needed to get a good centering mark. A couple whacks with the hammer and I was good to go. I started with an 1/8" right handed cobalt bit. I got off line a little and the bit was going in crooked. No turning back once you get too deep. I switched to a left handed 3/16" bit. I was surprised that it didn't come out while drilling. I drilled all the way through the stud. I tried a spiral Ez-out but I didn't reef on it. It didn't feel right so I stopped. I squirted PB in the hole and let it sit. I'll get a different style of extractor and try again. I will probably wait until I get all of the broken studs drilled and the remove the manifold before attempting removal.
posted by 166.137.248...
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