 2.0 liter exhaust stud bolt centers |
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| RangerDick |
 Jan 31 2023, 09:22 PM
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#1
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Newbie  Group: Members Posts: 18 Joined: 15-May 17 From: Burlingame, CA Member No.: 21,104 Region Association: Northern California  |
Howdy. Snapped off an exhaust stud while replacing the heat exchangers. Going to make a drill guide that will index off the remaining stud so I drill in the center of the snapped one. But I need to know the bolt centers between the two studs. Anyone know that measurement? Thanks in advance.
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| ClayPerrine |
Feb 1 2023, 06:55 AM
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#2
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Life's been good to me so far..... Group: Admin Posts: 15,410 Joined: 11-September 03 From: Hurst, TX. Member No.: 1,143 Region Association: NineFourteenerVille 
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QUOTE(RangerDick @ Jan 31 2023, 09:22 PM)  Howdy. Snapped off an exhaust stud while replacing the heat exchangers. Going to make a drill guide that will index off the remaining stud so I drill in the center of the snapped one. But I need to know the bolt centers between the two studs. Anyone know that measurement? Thanks in advance. The bolt patterns for the /4 engines on the exhaust studs are all the same. Find an early 1.7 heat exchanger with the cast flange and cut it off. It makes an excellent drill guide for the broken stud. Install it without the copper gasket so it aligns correctly. Clay |
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| VaccaRabite |
Feb 1 2023, 08:45 AM
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#3
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En Garde! Group: Admin Posts: 13,423 Joined: 15-December 03 From: Dallastown, PA Member No.: 1,435 Region Association: MidAtlantic Region |
Bear in mind, even with a drill guide you will probably ruin the threads and have to move up to a step stud. Not a huge issue. Also, make sure you have a drill stop on your bit, and that you really measure how deep you can go. When you tap, you will need the taper or plug tap to get started, but this is a case when you REALLY want that bottoming tap to get the last threads in your bore. Otherwise, you will not be able to seat the last 3/16th or so of your new exhaust stud.
Before you try drilling, have you tried building the stud back up with weld and welding a nut to it? The weld wont stick to aluminum, and the heat from welding will help break the crusty bond the old stud has with the head. Zach |
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| infraredcalvin |
Feb 1 2023, 08:55 AM
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#4
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Distracted Member Group: Members Posts: 1,507 Joined: 25-August 08 From: Ladera Ranch, CA Member No.: 9,463 Region Association: Southern California
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| GregAmy |
Feb 1 2023, 09:18 AM
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#5
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Advanced Member Group: Members Posts: 2,267 Joined: 22-February 13 From: Middletown CT Member No.: 15,565 Region Association: North East States
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Use an old exhaust stub/flange as a guide. Bolt it to one stud and use the other hole as a guide. Replace it with a TimeSert or, if needed, a BigSert.
I've got a recalcitrant exhaust stud with my name on it. Tried to back out and got stuck when I removed the headers on the race car, and now won't go out or in, it's galled in place. I'm putting that unhappy job off for as long as possible... |
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| ClayPerrine |
Feb 1 2023, 02:59 PM
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#6
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Life's been good to me so far..... Group: Admin Posts: 15,410 Joined: 11-September 03 From: Hurst, TX. Member No.: 1,143 Region Association: NineFourteenerVille
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QUOTE(VaccaRabite @ Feb 1 2023, 08:45 AM) Before you try drilling, have you tried building the stud back up with weld and welding a nut to it? The weld wont stick to aluminum, and the heat from welding will help break the crusty bond the old stud has with the head. Zach (IMG:style_emoticons/default/agree.gif) If you have anything of the old stud sticking out, weld a nut on it. I use a gas torch for that. The heat helps break the stud loose from the head. |
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| Morrie |
Feb 1 2023, 09:03 PM
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#7
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Member Group: Members Posts: 181 Joined: 8-October 07 From: Cedar Park, Texas Member No.: 8,198 Region Association: Southwest Region
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I like to use the reverse drill bits in a cabinet screw centering guide. Keep tapping the trigger on the drill as you go in and often it will catch and back out the screw. All this stuff is available on Amazon for not much money.
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