Broken stud near exhaust port...what do I do?

[Craig]

Hi, I'm Craig, and I was just referred here by MoparKid...I have a big problem...I just got my headers today, reaching the end of my engine build up and I saw a problem. I was placing the headers next to my exhaust ports to see how it looked and I noticed that one of the studs that hold on the headers is broken/cut. I would usually just take it out and replace it, but the problem is that the break/cut is below the line of the surface. What do I do? I will add some pictures tomorrow when I wake up, but I just got off work and I'm really tired...thanks for the help!

[451 valiant]

You'll have to drill it out and use an easy out. If the engine is in a car, hopefully it's a hole you can get at with a drill or the head will have to come  off. If it's not in a car it shouldn't be too bad.  With an easy out set you drill a hole in the stud and insert a  tool that screws into the stud and backs it out. This is the best way that I know of. Otherwise you can drill the stud completely out and rethread the hole with a tap.

[Bigcube]

On iron heads a few of the exhaust studs go into the waterjacket... I think it's the end ones. Yup, take the head off to fix it as stated above 

[Rocky Ak]

if it's not broken off too deep you can get or make a brass or copper washer that has an inside hole the same size as the stud. hold it over the broken stud and weld (a wire feed works good for this) a bead to the broken stud up through the hole and then get a large nut and with it over the washer, weld from the bead to the inside of the nut...wait for it to cool on it's own (if you accelerate the cooling process with water you will harden the weld to the point of it becoming brittle and it will break) then use a wrench and back it out.....or just remove the head and do as has been suggested

[Ciscodog]

Yup - try the welding trick

[pwmax]

Well, from someone thats taken out literaly hundreds of those studs, your not getting it out with an easy out. Its rusted in there, thats why it broke off. I do it in the seat and guide machine, and install a helicoil. Using the machine, makes it a snap, but, for you at home, its a little trickier. You will have to drill out the old bolt, then install the appropriate helicoil. Its no biggy really, and isn;t all that hard. It is imortant to drill and tap the hole straight though, otherwise, the helicoil will bind, and the bolt will only go in a little ways. If the heads are on the engine, you will have to take it off, if its in the car. If its on the stand, you can leave the head on. I would make a drill fixture though, or, use a square, and a couple sets of eyes, so you dril it straight, and tap it straight. Or, if its off the engine, bring it to a machine shop, and have them install a helicoil for you. It would probably be a wash, as far as cost. You would probably have to buy a helicoil kit anyhow.

Frank
Advanced performance
www.get-ap.com

[GON_RACIN]

another trick you can do that i havent seen anyone talk about for removing broken studs that are flush or below is using the tap drill for that particular thread to drill out the stud.  As i recall those studs are 3/8-16 thread, so you just look at a drill and tap chart and figure out what size drill you need.  For a 3/8-16  thread you'll need a 5/16 drill.  Obviously you'll have to take the head off, but you  just center punch the top of the busted stud, and drill down through it, take care not to go to deep.  You really need to be careful that you stay ON CENTER. Then you just take a 3/8-16 tap and chase out the threads of whats left of the busted stud.  I've done several heads like this in the past with good results.  I like this way better b/c you can avoid using a helicoil, and if for some reason you mess up and get off center, there is still enough meat that you can use a helicoil if neccessary.

[Craig]

Alright guys. Thanks a lot! Now I just gotta DO it...

[moparteacher]

You can also try hot wax. Heat the area around the stud with a small torch or flame. Melt a stick of wax from a candle etc. onto the stud and allow to cool. The wax will melt and seep into the threads and aid in the stud removal with the easy out. Good luck

Moparteacher