Sheared Exhaust Studs getting you down?

[Admin-bloke]

This plate please, just in case the worse were to happen.

I'd rather have it and not use it, than not have it and need it !

No rush though, whenever

[Chriss]

Chris: Stud extractors only really work if you have 10mm of stud sticking out, any less and you'll chew it into a point.

Ah yes indeed, maybe I have mostly been lucky but I tend to find either the stud comes out with the nut or if the stud breaks it breaks flush with the manifold still giving enough stud sticking out. Often I found studs were still plated at the very end that was in the head even though the opposite end was rusted massively.

Although I do wish I had your patented tool for drilling as mostly the ones that I had problems with have been at the back by the chassis leg. Your tool would have been a god send

My technique is start with the 11mm socket and start attempting to turn the nut but only applying light pressure then take a hammer and whilst keeping pressure on the nut tap the socket near the head and just keep tapping and they generally give way, then when they move get WD40 / plus gas sprayed in and maybe tighten up the nut again slightly and work in the WD40. This can often take several minutes of tapping though so patients is a virtue Then when all the nuts have gone remove manifold and repeat for the left studs using the stud extractor. Of course weeks of soaking the area in WD40 would be helpful too

My experience with easy out type stud extractors has mostly ended in my tears as the extractor has broken then its either grind it out using lots of Dremel hardened grinding bits or potential head into a machine shop

[Darren C]

Your spot on Chris.

Patience is the best tool in your toolbox.

Paul,

New plate made and posted this morning.

Good luck.

Regards
Darren

[dmc4087]

My experience with easy out type stud extractors has mostly ended in my tears as the extractor has broken then its either grind it out using lots of Dremel hardened grinding bits or potential head into a machine shop

My experience too. I was a firm believer that 'Easy-out' is an oxymoron.

[willinot]

Well, that was a long weekend. Just back home after sorting the exhaust studs out......let me re phrase that, just back home after working on the DMC while Thomas (dmc4087) and Eamon (albino944) sorted the studs out.

HUGE THANKS guys, really appreciate it, I'd have been lost.

Also, Darren, your a gentleman and a scholar, the plate arrived in the nick of time and served its purpose we'll. Engine in and studs out.

Sods law though that as soon as the job was done the orignal one turned up again too.

If you pm me your address I can send you one back to you with whatever costs I owe you or if Nick still needs one and you want to arrange with him I can post onto him too.

Just le me know.

Thanks again to everyone for their help.

Cheers

Paul.

[Darren C]

No Problem Paul, you are most welcome. Just glad it worked out for you

Please send the un-used "found one" (just in case the pilot holes have worn oval on the one you used) over to Nick T. Silly posting it to me then me posting it to him.

Kind regards
D

[mknowlton]

So just as me and Barry were about to finally finish our project car (VIN 3283) we develop a chugging exhaust which turns out to be the seal between the right hand manifold and the cylinder head. Rather than just put a bit more pug on top of that applied by the PO, we decided (as always) to bite the bullet and undertake a proper repair.

Just as well as it turns out to be two snapped manifold studs.

We thought it only right to bump this thread and thank Darren for the loan of his very effective jig with a few photos of yesterdays operation as we know that you all love a bit of engine porn!

Jig with washers and insert stuck in place with a little bit of grease.

man1.JPG (118.35 KiB) Viewed 3832 times

The first thing to do was lift the car up on the ramp and remove the oil filter and starter motor, the alternator was also slackened off and swung out of the way. The two broken studs were top left and top right.

As you can see, not a lot of room.

man2.JPG (98.65 KiB) Viewed 3832 times

Drilling out the first one seemed to take ages but you just can't rush it, we used a pneumatic angle drill for this as it was pretty compact.

Drilling out the first stud, we managed to retap the hole afterwards

man3.JPG (95.97 KiB) Viewed 3832 times

The second hole was a bit more accessible

Jig in place on the second hole

man4.JPG (85.09 KiB) Viewed 3832 times

This one drilled out pretty quickly.

Pilot hole drilled lovely and central

man5.JPG (132.38 KiB) Viewed 3832 times

We managed to wind it out with a stud extractor

Removing the snapped thread with a stud extractor

man6.PNG (339.54 KiB) Viewed 3832 times

Now, that's a sight for sore eyesI

manlast.JPG (77.78 KiB) Viewed 3832 times

So there we have it, success and thanks again to Darren C for the loan of the jig.

We boxed everything back up and managed to get a run on the engine before going for a well deserved pint last night. No more exhaust leaks! So glad that it went well.

We have just seemed to have no end of little jobs crop up in our efforts to finish the work on this project car but we are nearly there now with just a final tune and a couple of minor jobs to finish off.

When I get round to it I will update our original thread on the project car as its been a while now!

[Admin-bloke]

Beautiful work. I do love engine pics

[dmc4087]

Great work, its a hateful job that.

[bandit]

Nice one Mike, never a great task, but all good