snapped exhaust manifold stud. and snapped stud extractor.

[caibs]

so i've got a bit of a problem.

i found a snapped stud in cylinders 1,2 & 6. 1 and 2 came out easily enough, 6 did not. we got the hole drilled dead centre and the snap-on stud extractor snapped off in the stud. no idea what to do now, you cant get to it with skinny nose pliers. tommorow we're going to try to drill it so it catches and unscrews, any other suggestions are welcome.

[Cuts]

your in a world of pain my friend

ide go to town on it with inox or some other pentrant.
then use some loctite freeze off spray and go right to town on it...prehaps past town and onto the next town.

[caibs]

haha i live in perth. there are no nearby towns.

there isnt even the option to drill it out and helicoil it anymore. fuck!

[Cuts]

spark eroder prehaps, duno if these are mobile yet if not take the head off and take it too someone

[pope]

Tungsten Carbide dremel nibbler got me out of the same situation. Only tool i could fins that would make a dent in the snapped easy out.

[caibs]

hmmm havent heard of them before. do you know where abouts would i be able to buy one?

[Cuts]

nubco/blackwoods kinda place would be your best bet.

[caibs]

hmm dont think we have them in perth. i'll scour the tool shops tommorow after work. thanks for your help guys.

any other suggestions are welcome. i'll try the lot.

[HAVABEER]

you'll probably find you wont be able to drill through the stud extractor, due to its hardness.

is there any of the stud poking out? you could try geting a nut on and if you have a welder weld the nut onto the stud and try turning that (after a good soak in WD40 etc)

heat it up with an oxy?

[StuC]

I've drilled through a snap-on stud extractor before but i was using a carbide snap-on drillbit. $120 bux each. And this was to get a snapped manifold bolt out of a 63 AMG motor. Very very scary!

Basically that bolt isnt going to come out by undoing it at all - ever. Your best bet may be to use a small drill bit and drill around the stud extractor and basically bore around it. Don't go outside the diametre of the original stud. Go as far deep as you can without drilling past the end of the stud. You're basically trying to drill the bolt out and have it collapse on itself. Use long thing punches and try and break bits off as you go. If you're successful and do it right the whole snapped bolt should come out and you should be good to run a tap through. If you mess it up, upsize it and helicoil/run larger studs if they'll fit through the manifold.

[StuC]

PS: Good luck!

[caibs]

stuc: fucken wow. 63 amg i bet you were shitting bricks ahaha. i have the fortune of the help of my friend whos a heavy duty diesel mechanic with literally a ton of tools on the back. ill see if he has carbide bits, who knows. otherwise that drilling around it idea isnt too bad. we even have one of those tiny snap-on flexible cameras to help. im sure its not as easy as it sounds, but i get the idea haha. if only they made mini hole saws.

the bright side is, the manifold does indeed have quite large holes so a bigger stud is definately an option.

many thanks, rep for you all. ill keep you posted with the outcome tommorow

[reecegze]

take the head off and take it to a spark erosion place. Easiest way possible, ull never drill through the ez-outs with normal drill bits.. Try using a masonry drill bit, its worked for me before if you willing to try things first

[thechuckster]

see if you can migweld something (larger bolt?) onto the broken bits. The heat might help free things up as well as having an object to get a drip on.

[StuC]

I actually just thought of that when i woke up this morning chuck. Just be careful not to put too much heat into the thing, but at the same time make sure you get a decent weld on it. Ive also used this on various snapped bolts with good success.

i just re-read and saw that you dont have much space to work with. You may need to take the head off to get a good go at it unfortunately, but at least if its out you'll be able to be a little more creative as to what you can use.