 Yet Another Way, to Remove Broken Exhaust Studs from Aluminum Heads |
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| 76-914 |
 Jan 23 2023, 12:11 PM
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#1
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Repeat Offender & Resident Subaru Antagonist  Group: Members Posts: 12,968 Joined: 23-January 09 From: Temecula, CA Member No.: 9,964 Region Association: Southern California 
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| Root_Werks |
Jan 23 2023, 01:51 PM
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#2
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Village Idiot Group: Members Posts: 8,001 Joined: 25-May 04 From: About 5NM from Canada Member No.: 2,105 Region Association: Pacific Northwest
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Done both, welded material on and rotated out. Oil and ViceGrips, mostly works.
Had good luck with reverse drill bits. Start as small as possible and keep upsizing. Usually the friction heat and constant reverse torque turn out the broken stud. |
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| 76-914 |
Jan 23 2023, 04:32 PM
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#3
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Repeat Offender & Resident Subaru Antagonist Group: Members Posts: 12,968 Joined: 23-January 09 From: Temecula, CA Member No.: 9,964 Region Association: Southern California
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QUOTE(Root_Werks @ Jan 23 2023, 11:51 AM)  Done both, welded material on and rotated out. Oil and ViceGrips, mostly works. Had good luck with reverse drill bits. Start as small as possible and keep upsizing. Usually the friction heat and constant reverse torque turn out the broken stud. Yes, me too. But I'd never tried to weld a broken stud that was recessed in the head. BTW, a 4" pipe wrench works much better than vice grips as it continually tightens its grip with additional force. IOW, it won't slip like vice grips. |
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| rgalla9146 |
Jan 23 2023, 08:55 PM
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#4
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Advanced Member Group: Members Posts: 4,320 Joined: 23-November 05 From: Paramus NJ Member No.: 5,176 Region Association: None
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QUOTE(76-914 @ Jan 23 2023, 05:32 PM) QUOTE(Root_Werks @ Jan 23 2023, 11:51 AM) Done both, welded material on and rotated out. Oil and ViceGrips, mostly works. Had good luck with reverse drill bits. Start as small as possible and keep upsizing. Usually the friction heat and constant reverse torque turn out the broken stud. Yes, me too. But I'd never tried to weld a broken stud that was recessed in the head. BTW, a 4" pipe wrench works much better than vice grips as it continually tightens its grip with additional force. IOW, it won't slip like vice grips. (IMG:style_emoticons/default/agree.gif) A 4" pipe wrench works very well. Much like a pipe wrench a vise grip works far better when positioned perpendicular to the stud and rotated with the upper jaw dragging the stud rather than pushing......the principle that makes a pipe wrench work so well. I've also had luck welding onto a surface broken stud.....~60% success |
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| infraredcalvin |
Jan 24 2023, 01:02 AM
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#5
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Distracted Member Group: Members Posts: 1,379 Joined: 25-August 08 From: Ladera Ranch, CA Member No.: 9,463 Region Association: Southern California
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Sheesh, he already had the welder out…
Weld a nut, use a socket in both cases No galling, can use extensions to avoid spark plugs etc… |
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| ClayPerrine |
Jan 24 2023, 06:26 AM
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#6
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Life's been good to me so far..... Group: Admin Posts: 14,640 Joined: 11-September 03 From: Hurst, TX. Member No.: 1,143 Region Association: NineFourteenerVille
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If there is any of the stud sticking out, I use a oxyacetalene torch to weld a nut on the remainder of the stud. The heat from the torch helps to release the stud from the head.
For one that is broken off inside, I make a drill guide jig and use a left hand drill bit that is slightly smaller than the broken stud. For a 914 exhaust stud, I use the cast end off an early heat exchanger as a drill guide. Patience is the key. |
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| r_towle |
Jan 24 2023, 03:36 PM
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#7
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Custom Member Group: Members Posts: 23,870 Joined: 9-January 03 From: Taxachusetts Member No.: 124 Region Association: North East States
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would you mind posting the pic in the first post?
Im not seeing anything and I love seeing how others solve things. rich |
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| 76-914 |
Jan 24 2023, 06:58 PM
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#8
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Repeat Offender & Resident Subaru Antagonist Group: Members Posts: 12,968 Joined: 23-January 09 From: Temecula, CA Member No.: 9,964 Region Association: Southern California
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QUOTE(r_towle @ Jan 24 2023, 01:36 PM) would you mind posting the pic in the first post? Im not seeing anything and I love seeing how others solve things. rich Rich, here is the link to that on YouTube. try this. https://www.youtube.com/watch?v=Oqs-08ATRyU |
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| rick 918-S |
Jan 24 2023, 07:29 PM
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#9
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Hey nice rack! -Celette Group: Members Posts: 20,010 Joined: 30-December 02 From: Now in Superior WI Member No.: 43 Region Association: Northstar Region 
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I weld through a washer. This protects the aluminum surface then weld a nut to the washer.
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| r_towle |
Jan 24 2023, 07:41 PM
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#10
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Custom Member Group: Members Posts: 23,870 Joined: 9-January 03 From: Taxachusetts Member No.: 124 Region Association: North East States
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QUOTE(76-914 @ Jan 24 2023, 07:58 PM) QUOTE(r_towle @ Jan 24 2023, 01:36 PM) would you mind posting the pic in the first post? Im not seeing anything and I love seeing how others solve things. rich Rich, here is the link to that on YouTube. try this. https://www.youtube.com/watch?v=Oqs-08ATRyU Weird apple crap Shows up fine on my iPhone. Does not show up at all on my older MacBook Sometimes Apple needs to stop trying to sell more HW and try supporting what they already sold. |
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| rick 918-S |
Jan 24 2023, 09:27 PM
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#11
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Hey nice rack! -Celette Group: Members Posts: 20,010 Joined: 30-December 02 From: Now in Superior WI Member No.: 43 Region Association: Northstar Region
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I weld through a washer. This protects the aluminum surface from spatter or gouging then weld a nut to the washer.
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| BillC |
Jan 25 2023, 01:05 PM
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#12
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Member Group: Members Posts: 498 Joined: 24-April 15 From: Silver Spring, MD Member No.: 18,667 Region Association: MidAtlantic Region
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Aluminum has a larger coefficient of thermal expansion than steel. This makes it much harder to remove steel bolts from aluminum heads when cold, because the aluminum shrinks more in the cold and "clamps down" on the steel bolts.
But, if you first run the engine for a few minutes or use a propane torch to warm up the head, it will make removing the bolts much easier. |
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