Snapped exhaust stud :(

[Dazza]

Only use the silver Neverseize on anything made of aluminium. The copper Neverseize will dissolve aluminium so you just have a bigger hole where your thread once was.

[88cameron88]

re. having stainless studs in spare head

not really winning there.
stainless studs are the worst for snapping, and hardest to get out.
mild steel all the way for exhaust

[TTV8RA23]

^^ Im with him, stainless studs not really ideal. they are the worst for picking up and snapping. I dont like the idea of running a die down the stud as this normally cuts undersize which is not what you need. give them a good wire brushing and a small amount of antiseize and tap the holes out with CRC as a tapping lube and youll be laughing. I work in an engineering shop and you would not belive the amount of heads blocks turbos etc etc that are brought in with broken bolts in them that people have tried to get out. Its fucken painfull cos 95% of the time they have either a broken drill in them or broken EZ out, sometimes both. This makes it a bit more of a challenge but still can be done with alot of time and patience.

[TERRA Operative]

I just removed a stud out of a turbo exhaust housing that a mate snapped off.

Turned out pretty easy in the end. I just drilled it out to *just* under the inner diameter of the threads, then used a punch and hammer to collapse the remaining stud inwards (there was a mm or so poking out the top). All that was left to do was to screw/rip it out with a pair of pointy nose pliers.
I just used lots of CRC and ran a tap through all the threads afterwards and it was all done in about 15 minutes.