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 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.

Left side today

Right side today

Not to bad inside though

it depend on how good your are with a drill bit

you could always get a dremel and slowly grind out the stud to weaken it and then try the EZ out method....

snap on makes some nice lefthand bits

I may have a left hand cobalt bit in the correct size. Let me check.

BTW.. I wil be offline the next few days... Yoder and I are going to Rusty's place in Kansas.

Larry, insides look really clean! I'd try soaking and some method of ez-out. One way or another it will have to be drilled by you or someone. Using a left-hand or reverse bit and the ez-out stuff might do the trick (after lot's of soaking!).

have you asked the 928 guys if anyone has a drilling fixture?

QUOTE (Mueller @ Jan 13 2005, 01:57 PM)

have you asked the 928 guys if anyone has a drilling fixture?

Im going to I just got side tracked in the sandbox.

Yep, cobalt bit and ez out plus lots of soaking with PB Blaster.

Geoff

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!

Left side came out no problem with the EZ out.....the right side was too deep to do the welded washer thing so I used the EZ out on it and things went to shit. I got it drilled and as I was starting to remove it the phone rang and startled me I jumped putting a side load on it and snapped it off in the head. After much cussing and tossing of tools I walked away for today. I know I can get it out it will just be a big pain. Time for beers

cobalt bit will drill out the ez out.

Did you break the EZ out off in the bolt? I dont think cobalt will cut that out. Try carbide and buy more then one bit. Be carefull!

QUOTE (14Maschine @ Jan 14 2005, 03:03 AM)

Did you break the EZ out off in the bolt? I dont think cobalt will cut that out. Try carbide and buy more then one bit. Be carefull!

Yes it id dead center in the stud about a1/16 into the head hole. No damage to the head...yet

Just a update. I got a carbide bit for the dremill and slowly took out the center around the bit and walla the EZ out tip is out then you know how some times you think lightning cant strike twice I get out the drill and drill deaper into the stud and get a nice fresh ez out. (flash of light and a bang here) We need a Dumb Ass smilie Broke off number 2 so I am off to get a fresh carbide bit.

If you use a reverse drill bit, seems like 75% of the time, the stud will turn out while you are drilling it. I need to get another couple of those drill bits.