Broken stud

[Rikki Kitto]

Just thought I'd post a pic of my nightmare, 3hrs very careful drilling to get it out

[mcandmar]

Nightmare, best solution is get a machine shop to mount it in a pillar drill, drill oversize and fit a heli coil or similar. Mistake i made i was trying to use a reverse thread stud extractor which snapped off and left a piece of hardened steel in there. Took a few hours and a handfull of drill bits to get it all out. Heard of people having success welding a bolt to it, the process of arc welding can also free up the seized threads making it easier to unscrew.

[Rikki Kitto]

All good it's out now, just got to sort the insert out and re-tap. Any suggestions on helicoils or chemical metal and re-drilling tapping?

[mcandmar]

Havent installed them myself so cant be much help, heli coil and time sert seem to be the most common options that folks use.

[s2_bo]

Heli coil has to be spot on though, if your a couple of mm off with your hole the bolt wont go in when you refit the manifold.

Good luck removing the others, i snapped a load when i did mine but they all came out with reverse thread extractors, just make sure you get the whole dead on centre with a pilot and then drill out to max size.

[Greg_S]

Yeah get it to a machine shop to remove, otherwise you risk knackering the head too. Happened on one of my exhaust studs years ago, luckily leaving about 4mm protuding which we were able to use to remove the stud

[Error404]

they are so easy to snap, I always heat them right up now before trying to remove them, seems to do the trick

[JP]

Mate of mine chucks them on his mill. Drops right down the middle, picks the thread out and runs a tap down them to clean them up at £10 per stud. No inserts helicoils or chemical metal needed.

[SE_30]

Soak them with a good penetrant overnight, then heat up the area surrounding the stud to expand, it's always done the trick with mine. Good luck

[Rikki Kitto]

To be honest was thinking of leaving well alone, they ones still intact seem fine they have worked for twenty years why upset them? or is this not a good option?