broken exhaust stud update, where do I buy a stepped exhaust stud ? Options

[brant]

I'm trying to change out a snapped off 4cylinder exhaust stud
its snapped off pretty short... between the head and the push rod tubes... nothing sticking out.

I can only get one nut on, not two

I've tried heat, pliers, etc...
I have a set of metric stud extractors.. but they are too big of diameter to fit on the stud. (the stud is pretty close to the side of the head)

I'm going to try and borrow a welder tonight and weld a nut on
does anyone know of any other trick or tool that would work in such a tight location?


brant

[worn]

I'm trying to change out a snapped off 4cylinder exhaust stud
its snapped off pretty short... between the head and the push rod tubes... nothing sticking out.

I can only get one nut on, not two

I've tried heat, pliers, etc...
I have a set of metric stud extractors.. but they are too big of diameter to fit on the stud. (the stud is pretty close to the side of the head)

I'm going to try and borrow a welder tonight and weld a nut on
does anyone know of any other trick or tool that would work in such a tight location?


brant

You are fighting electrolytic bonding between the steel stud and the aluminum head. If it is bad, and sounds like it is, the best weapon is heat. Problem is it gets pretty scary. The old guys who say to get out the acetylene and heat the nut or bolt to glowing red know what they are talking about. BUT with gas and oil it is DANGEROUS. One good thing is you can work up to it by heating to the limit of your comfort zone and then trying the stud - just don't break it. If it seems like it won't move, try more heat. Also after heating, spraying with penetrating oil works well because it soaks into the hot joint better. Again DISCRETION, because what works is also at the oil flash point. An advantage is that the aluminum carries heat very fast so it is fairly hard to damage the aluminum by heating the stud. There are electric stud heaters too, but most people can't afford them.

Welding blankets from harbor Freight, a full bucket of water in case your hand gets hot, and fire extinguishers.

If all this sounds like pyromania, it isn't meant to be, but it has worked for me.

[worn]

[quote name='worn' date='May 15 2012, 09:54 AM' post='1675890']
[quote name='brant' post='1675822' date='May 15 2012, 08:29 AM']
I'm trying to change out a snapped off 4cylinder exhaust stud
its snapped off pretty short... between the head and the push rod tubes... nothing sticking out.

I can only get one nut on, not two

I've tried heat, pliers, etc...
I have a set of metric stud extractors.. but they are too big of diameter to fit on the stud. (the stud is pretty close to the side of the head)

I'm going to try and borrow a welder tonight and weld a nut on
does anyone know of any other trick or tool that would work in such a tight location?


brant
[/quote]

In re reading it sounds like your problem is more about grabbing the stud. I had thought at first it was an issue of it breaking off during turning so it was stuck on.

This sounds stupid, but I would have thought that a big - @ss vise grip would lock on with a torque powerful enough to break the stud. Guess not. Your stud extractor if cam action might work if you added a small bolt parallel to the stud to take up space. Good luck. I have a small jar that I put the victory extractions in - drilled out, or some other heroics. Not that full I am afraid, but fond memories to build courage.