Snapped a rusted off exhaust stud off, and ended up mangling the threaded hole to get the remnants out. Anybody know where I can buy an exhaust stud with one end enlarged to 10mm diameter? Any other solutions you guys have done in the past? Thanks, Steve

I used a heli coil...how bad is it?

McMaster-Carr has everything. If you can't find one with the "mixed sizes", you can fix the buggered up hole with a helicoil.


Otherwise, it can be welded up, bored and retapped to orginal if you are concerned about originality.

McMaster-Carr

I found quite a few pieces of obscure metric hardware for my Moto Guzzi restoration 10 years ago which were PERFECT replacements.

Try to find a VW or off road parts shop as they carry those studs. In the San Diego area they sell them at VParts among others. They also come in different lengths.

The heli-coil is my last resort, as it would indeed work. I'm not concerned about originality, but I just figure a larger stud would have greater strength from a greater length of thread; I heli-coiled one of them on the 1.8 I have in the car right now, and it usually threads out everytime I drop the exhaust. Since I'm in no hurry, I should be able to find the stud for the 2.0 that's going in in the next couple months. Steve

FAT performance
Car craft in riverside CA

try raby first....

I beleive AA sells a 9MM (first cut) and a 10MM stud. It is 8MM on the manifold side.

I have 8mm versions, 9mm versions and the whopper at 10mm . All these are chromoly steel and won't break!

Heli coils can pull out. I had one that was ruined. I used a threaded insert. This is a called a "KeyLock Thread repair kit". I got it from McMaster Carr. You drill out the hole for a 12 x 1.25mm thread. I needed to grind my tap to get to the bottom. The insert is threaded in this hole. There is then a tool that is in the kit that is used to drive 4 small keys that are along the outside of the insert. This Locks the insert in place. The Insert is Stainless Steel. This was not cheap but made a very good repair.

Mark