Exhaust Stud Replacement

Bought a good running motor,one stud was missing in the manifold...and of course the reason was somebody made a half a-- effort to get a broken stud out and broke off a tap or easy out off.Tried to heat it to take the temper out,no help...saw a guy once take a small cutting tip and blow it out enough and chase the threads.Not sure the next step,I do have a few threads...tomorrows another day....any secrets?

 

Taps are brittle enough you can sometimes break them out with a small punch. Start working on the individual flutes from the side as much as you can. Then smack it dead center. It will take a long time. Be patient. You'll be literally chipping away at it.

 

Carbide drill bit and oil might work,,,,,if you break that bit good luck to ya.

 

If it's broke off flush or close to it:
weld washer to broken stud
weld nut to washer
while hot saturate with penetrating oil
user box end wrench and tap with small hammer as you apply pressure to back it out
as soon as it moves stop add more penetrating oil and let sit
should be easier to remove a few hours later

 

I have done this a couple of times, it is scary, but, it works. Take a welding torch, the one hole tip, set to a neutral flame, heat the tap until it is red hot and sparking, turn off the gas, acetylene, and let the oxygen melt the tap out. A torch will not cut cast iron, per say, you can then run a tap through and clean up the threads. I done this a couple times, while holding my breath, but both times it came out good. Good luck

 

Thanks...did the punch and torch,just too timmid,time to hike up my big boy pants and get at it....

 

I understand, the first time it was not my car so I was not too scared, but when it is your car things are a little different. Worse case is you will have to put a Helicoil in it. They do work too.

 

Remember, god hates a coward.

Which one is broken off? Some are in the water jackets which will help. Is the engine an f head or 225?

 

I'm on that highway to hell,LOL...found an excuse to put it off,a friend needs a threshold made....lotsa figuring don't ya know.It's the stud on the back end of a F-161,going to give her what for tomorrow for sure....

 

Thanks for the help and push guys...used a welding tip and melted out the hardened material and got it so a drill bit would cut it...took about 3 hrs. to do......