Exact measurement needed, Distance between exhaust studs Options

[saigon71]

I'm in search of the center-to-center measurement on stock 2.0 exhaust studs.

Thinking about building a drilling jig to help me drill one out. My concern with just measuring my existing ones is that they may be slightly bent.

I've probably only got one shot at this, so I want it to be exact.

Thanks!

[larryM]

look at the Stomski tool for ideas on how to design your jig project - it is not a direct application for your heads, but may help you figure out a setup

Stomski stud tool

2 yrs ago, I b'ot one of these from Pelican to do my 3.2 - it is invaluable - i'll never ever need it again, but it was worth every penny at the time

.

[saigon71]

look at the Stomski tool for ideas on how to design your jig project - it is not a direct application for your heads, but may help you figure out a setup

Stomski stud tool

2 yrs ago, I b'ot one of these from Pelican to do my 3.2 - it is invaluable - i'll never ever need it again, but it was worth every penny at the time

.

I saw that one this morning while researching...very nice. If I can get the exact measurements between exhaust studs, I think I can make a suitable jig out of flat bar steel that will keep the drill straight & true.

[larryM]

you should be able to get "exact enuf" by measuring a pair of intact studs per your pictures with a precision vernier caliper

- you have likely soaked the hell out of it with Kroil and put lots of pinpoint heat on it with an Oxy-Acety torch already ?? - sometimes the heat will help the Kroil penetrate

fwiw - i have successfully hand-drilled these things multiple times - first make sure the broken end is ground FLAT so you can center a self-starting bit on it - you start with a SMALL dia tough high speed steel RH drill bit & once you have a deep pilot hole you can progressively switch to larger left-hand bits - the things are tough, so expect to waste a couple bits

sometimes the thing will come loose with the left-hander when you have it drilled out to a shell (the stomski tool uses LH bits)

- or you can try an easy out once it is very thin (and soaked & heated)

worst case - if you miss exact center - you can buy step studs to fix these 10mm to 8mm - just drill & tap that slightly offset hole to 10 - yup - i have also done that more than once

if you want lots of tips & good experienced advice on how to get studs out & what to do if they fail - go search Pelican for <exhaust studs>

start here - broken exhaust studs

look at the Stomski tool for ideas on how to design your jig project - it is not a direct application for your heads, but may help you figure out a setup

Stomski stud tool

2 yrs ago, I b'ot one of these from Pelican to do my 3.2 - it is invaluable - i'll never ever need it again, but it was worth every penny at the time

.

I saw that one this morning while researching...very nice. If I can get the exact measurements between exhaust studs, I think I can make a suitable jig out of flat bar steel that will keep the drill straight & true.

[saigon71]

(IMG:style_emoticons/default/icon_bump.gif)

Does anyone have the exact center to center measurement?

Thanks for the responses and advice.

[Valy]

I measured 60.5mm between the studs but it might be they are not 100% straight. Fitting a caliper between them is such a pain. I could only measure one port.

[larryM]

surely - one of us World guys has the oem Type 4 blueprints at hand and can scan them to answer this plea ????????????

maybe try posting this on SAMBA ?????????

- and let the VW gurus have a hand at the answer ?????

.

[saigon71]

I came up with a center to center measurement of 2.340" in case anyone else needs it.