HELP I dont want to pull the heads, You have seen this problem B/4 Options

[spare time toys]

I took the exhaust manifolds off the 928 engine today. I posted how at one point someone tried to seal the rear ports with JB weld. Rick posted a shot of a stud he welded a nut on. Well when I got the manifolds out of the way I find the studs broken off below the surface of the port (IMG:http://www.914world.com/bbs2/html/emoticons/sad.gif) Would you try a left hand drill bit and an EZ out or take the heads off and a quick trip to a shop? Here is the problem as I first found it.

[rick 918-S]

Larry,

That's what mine looked like. First clean the stud with a wire wheel on a drill. You have to be very accurate but find a washer the same size the stud was. Tack an ear on the washer you can attach the ground cable to. Use the ground clamp to hold the washer centered over the broken stud, turn up your wire feed heat, slow the wire rate slightly, start to weld. The weld won't stick to the aluminum but will weld the washer to the stud. Then plug weld a nut to the washer. Cool with compressed air. The heat cycles will loosen the stud. Slowly start to back out the stud with the nut. If the weld doesn't take you can always try the drill method. But I've never had luck with that.

BTW. Clamp the ground cable right on the washer. You can arc the bearings right through the oil if you have the ground in the wrong place!