How To Remove Broken Exhaust Stud From Cylinder Head

jfqc

Posted 11/29/2013 08:15 (#3478384) Subject: removing broken exhaust stud

se montana

any ideas on this one? stud is broken off in the cylinder head just a trivial deeper than flush (about 1/8"). what are my options?
tia,
scott nelsen

Posted eleven/29/2013 08:25 (#3478415 - in reply to #3478384) Subject: Re: removing broken exhaust stud

Leeds, North Dakota

Class 8 commodities? Personally I utilize cobalt $.25, MAKE sure y'all are centered, drill it out and put a helicoil in it, I have tried the welding washer trick and nut, seems a lot of time to make bolt harder to drill out, Scott. a4t-1600

Posted 11/29/2013 08:41 (#3478461 - in reply to #3478415) Subject: Re: removing broken exhaust stud

Dearfield Co.

Reverse cobalt bit brand certain you are centered.Hopefully when you make it thru the bolt a couple of times information technology will come up out with the bit.I used to attempt easy outs after the first bit went thru merely had more than borken out piece of cake outs to drill that way.Merely make certain you dont go to deep and strike h2o.If you take really tough ones heat the head with a small tip effectually the bolt hole to give some expansion of the cast to aid the fleck hook and spin information technology dorsum out------------------------------------------If the bolt is bottomed out in the head and thats why it bankrupt exist extra cautious. 4WD

Posted eleven/29/2013 08:50 (#3478476 - in reply to #3478384) Field of study: RE: removing broken frazzle stud

NE function of SW Iowa

If y'all determine to drill it, then get some tape and marker (put tape on) your drill scrap to the maximum depth, of the threaded hole = use a skillful, open hole equally your depth guide, to mark your fleck.

This style, yous shouldn't ever drill also deep and drill thru the cylinder head and into the water jacket.

It is SO Important that you spend the time to get as perfectly centered as possible, then if all else fails(= yous couldn't salve the original threads), at to the lowest degree you are centered for a helicoil installation.

FarmOR

Posted xi/29/2013 09:06 (#3478522 - in respond to #3478415) Subject: Re: removing broken exhaust stud

Eastern Oregon

Hanson sells a screw extractor kit that has matching left handed bits for every extractor. Very overnice set and works better than any other extractor I've used over the past 25 years. Sometimes, you get lucky and the left manus bit will break the offending stud loose, merely that's unlikely with a rusted up, heated up exhaust manifold commodities. Be careful to center dial eye, drill straight and center - starting with the smallest fleck and stepping up to about one-half the diameter, and don't strength the extractor and suspension it off. Try using a little applied heat around the stud and skillful luck... hwdcne

Posted 11/29/2013 09:11 (#3478534 - in respond to #3478476) Discipline: Re: removing cleaved exhaust stud

Soutwest Ks.

I had two or three broken exhaust studs on a 1370 Case years ago and I had a black smith come out. He didn't even bring an ez out or bits. He immediately welded a washer to the stud and just spun them out. Later on that experience I most always endeavour that first and most every time have practiced success. That stud will be very hard to drill and I incertitude that welding on it is going to make it much harder if any. I know Scottnelson knows his stuff merely in my feel I believe that welding a washer to the stud is about the but way anymore that blacksmiths use in my surface area to remove studs. My final experience with welding a washer to a stud was on the duals on my 9600. I had ii or three broken bolts that were recessed quite a long way and had proficient luck with the weld/washer fob and I am not an experienced blacksmith. Topshot

Posted 11/29/2013 09:19 (#3478553 - in respond to #3478534) Subject: Re: removing broken frazzle stud

Near Richmond, IN

I agree that your method is probably the best merely I'm having problem understanding how y'all weld a washer to a broken bolt/stud that is recessed in the hole. How do you go along it from welding to the pigsty itself? But curious so I tin try it if the demand arises old. Alberta Pioneer

Posted 11/29/2013 09:20 (#3478558 - in reply to #3478384) Subject: Re: removing broken exhaust stud

Warburg, AB

If you lot weld a washer on, sand off the zinc or apply acrid - a bugger to weld well otherwise. I've had good luck but the corporeality of rust is the determining factor.

Bruce

sri

Posted 11/29/2013 09:25 (#3478569 - in reply to #3478384) Discipline: RE: removing broken exhaust stud

nw pa

if the bolt is broken deeper than you feel is comfy to weld.. head to the nearest engine rebiulders and become some valve stem washers they take a deep loving cup to them that may fit into the recess. They will be difficult and may need to be heated and cooled to take some of the atmosphere out of them.

(valve stem washers.jpg)

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valve stem washers.jpg (6KB - 184 downloads)

4WD

Posted eleven/29/2013 09:25 (#3478570 - in reply to #3478534) Subject: Re: removing broken frazzle stud

NE part of SW Iowa

Welding works, when information technology works, BUT it will make information technology harder = drill bits won't even begin to bit, after yous fail with welding =I've had to use a carbide bit on a diegrinder and go thru the hardened area (nigh 3/16 deep) then I was able to drill again.

I'chiliad to the point, where I drill an pilot pigsty thru stud, eject penetrating oil into hole, thenlightly try an extractor, if information technology doesn't come loose, then I might move towards welding(plus the the eye hole, welding can even compress the broken stud even more) Now, if it was drilling good, I might just pace up to the side by side size and try a larger extractor, too. (simply don't get all "KingKong" when trying those extractors)

Until you guys take experienced failure, on welding, then you don't really know what your in for, timewise, after-the-fact.

ccjersey

Posted eleven/29/2013 09:32 (#3478584 - in respond to #3478384) Bailiwick: Re: removing broken frazzle stud

Faunsdale, AL

There are welding rods that have the correct flux to fill the hole with flux and weld volition not stick to the surrounding metal. These are more for larger sizes in my mind.

On your stud, I would start out past drilling carefully through it. If you are centered and an extractor won't get it out, just keep drilling larger until you cutting into the threads and so option the remains out/run tap in. If you drill off center, I go to a torch and blow out the remnant of the stud and then clean out the remaining threads with a tap.

It is much easier to blow out after drilling through the stud. And much easier still if the hole is non a blind i.

Edited by ccjersey xi/29/2013 09:36

muddrunner

Posted 11/29/2013 09:forty (#3478600 - in respond to #3478534) Subject: Re: removing cleaved frazzle stud

Westphalia Texas [central texas]

Have welded out a many of bolts with broken extractor in the bolt. Showtime thing take a good punch and drive the bolt inward ,this will help center the internal and external threads. Not a little tap but a good lick. Next weld a washer on with a hello blend rod ( HA alloy 500 ) some weld shops call them extruder rods. Practice not utilise wire feed ,6011 , 6013, 7018 ,will work if non a bad one, don't take that chance. Then weld a larger nut on the washer and bolt , inside of nut. Your trying to become as much heat in the bolt every bit possible, then walk away, let it cool on its own, let the commodities to compress., When y'all try to remove the bolt ,wiggle the wrench back and forth and it will slowly start to move. Have had to repeat this , but have never failed to get one out. Secret is the rod and patience. Good luck muddrunner

Posted 11/29/2013 09:48 (#3478612 - in reply to #3478569) Subject: Re: removing broken frazzle stud

Westphalia Texas [central texas]

Sri ,like the thought of valve spring retainers for washer. Top shot with the correct rod the flux volition menstruum to the walls of the hole. twraska

Posted 11/29/2013 10:15 (#3478673 - in answer to #3478384) Subject: RE: removing broken exhaust stud

Wallis, TX

Carbide terminate mill in a magnetic based drill, will cutting through a grade eight commodities like butter.

MCatSHF

Posted 11/29/2013 10:17 (#3478676 - in reply to #3478384) Subject: RE: removing broken exhaust stud

Sandy Hook, MB

Hello Jfqc

I'll presume bandage iron head. Quickest & easiest mode is to blow information technology out with O/A torch. Blow out slag with air hose, then chase the threads with a tap, done.

Topshot

Posted 11/29/2013 ten:xxx (#3478709 - in reply to #3478612) Subject: Re: removing broken exhaust stud

Virtually Richmond, IN

Thanks Muddrunner. I didn't know that.
1586

Posted eleven/29/2013 ten:52 (#3478758 - in reply to #3478384) Subject: Re: removing cleaved exhaust stud

Drill, heat/candle wax, proper removal tool. muddrunner

Posted eleven/29/2013 12:28 (#3478912 - in reply to #3478758) Subject: Re: removing broken exhaust stud

Westphalia Texas [cardinal texas]

1586 , would yous explicate how to utilize the candle wax, oasis't heard about the wax. campbell

Posted 11/29/2013 12:37 (#3478924 - in reply to #3478384) Subject: RE: removing broken exhaust stud

Fundamental ILLINIOS

Our JD service mgr. recommends these welding rods that stick to the stud but wont stick to the bandage. Never tried them myself but I have some to do this wintertime.
https://www.youtube.com/lookout?v=L4zohssWS7I
https://www.partsmaster.us/SitePages/products.aspx?Code=02010305 ekeller2

Posted 11/29/2013 15:49 (#3479238 - in reply to #3478384) Subject: Re: removing broken exhaust stud

So. IL

I drill a pocket-sized starter hole and so bulldoze a torx socket into it and back them out. Easy outs are junk in my view. ccjersey

Posted 11/29/2013 16:05 (#3479263 - in answer to #3478912) Bailiwick: Re: removing broken exhaust stud

Faunsdale, AL

Heat stud to cherry red and as information technology cools, utilize wax to it to melt into the threads. I have tried it several times and it wasn't magically effective in my hands. durallymax

Posted xi/29/2013 16:28 (#3479292 - in reply to #3478384) Field of study: Re: removing broken frazzle stud

Wi

Welding works sometimes, but the upshot is that it can brand the biggest mess if it doesn't work. If you can get perfectly centered, just start drilling with left handed cobalt bits, eventually you volition get up to a size where information technology volition spin out or an extractor will work. One time y'all get likewise big though the extractor will brand a mess.

ekeller2 - 11/29/2013 14:49 I drill a small starter hole then bulldoze a torx socket into it and back them out. Easy outs are junk in my view.

Might take to try that some time, how fast does information technology wear your sockets down?

Screw flute easy outs are junk, multi splined ones are dainty. They are designed to bottom out and so pull versus the spiral flutes which just keep trying to get deeper.

muddrunner - 11/29/2013 11:28 1586 , would you explain how to use the candle wax, oasis't heard almost the wax.

Its an old machinist trick, has to exist methane series wax and you have to be patient. Machinists often have a lot more patience than the balance of us.

farmboy99

Posted 11/29/2013 xviii:29 (#3479558 - in reply to #3478600) Subject: Re: removing cleaved exhaust stud

SE South Dakota

Why not utilise a wire welder?

Jim J

durallymax

Posted 11/29/2013 19:17 (#3479698 - in respond to #3479558) Field of study: Re: removing broken exhaust stud

Wi

farmboy99 - 11/29/2013 17:29 Why not use a wire welder? Jim J

Stick that gun upwardly to the hole and tell me how well y'all can see what you are doing? At present endeavour to weld without touching the sides. Some people can practice it just its tough. Granted my experience was with a stalk scroll bolt broke off 3/four" into the hole. Tried the welding idea with a Mig and failed, ordered a new shaft at that point.

1586

Posted 11/29/2013 22:32 (#3480137 - in answer to #3478912) Subject: Re: removing broken frazzle stud

muddrunner - 11/29/2013 xi:28

1586 , would you explain how to use the candle wax, oasis't heard well-nigh the wax.

Saw one removed this way and thought it would be my outset line. Soon as it'south hot you cool/melt the candle on it. Information technology was drilled out and the stud extractor got it going.

shaun3480

Posted 12/1/2013 11:22 (#3483010 - in reply to #3478384) Subject area: Re: removing cleaved exhaust stud

Phillips Co NW Kansas

I will also presume it is a cast head. I only did three of them in a GM6.0L however in the pickup. One was broken off flush with the manifold. That was easy to become out. The other two were broken off flush with the alum caput. I used a 5/16" washer then welded a nut to that. Tried using a smaller nut but concluded up going with a ane/ii" nut to go enough weld and oestrus to the bolt.

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