Extracting a broken exhaust stud

[Peter Connan]

I friend of mine recently purchased a 4.5 GRX, but it seems that I did not do the pre-purchase inspection carefully enough.

It transpires that one of the studs joining the exhaust manifold to the cylinder head is broken off.

Does anybody have any clever tricks for extracting it? I would prefer not to use an easy-out, as there is very little space to drill the hole and I have had pretty poor results with easy outs, they tend to break and then it becomes a real mission.

I thought of first trying to drive it out with a centre punch, and if that doesn't work to try to weld a welding rod onto it and turn it out with that, any better ideas?

Also, Nissan seem to feel that the manifold will need skimming, what do you guys think?

[Herrie]

Kan jy vir ons 'n foto laai sodat ons kan sien wat moontlik is?

[Peter Connan]

Kobus ek het nog nie self gesien nie. Die probleem is by 'n Nissan handelaar geidentifiseer.

Ek beplan maar vir "worst case", dat hy level of effens binne-in afgebreek is.

[Herrie]

As hy 'n bietjie uitsteek kan jy miskien 'n gleuf saag en hom met 'n skroewedraaier uit draai.

[Kagiso II]

Oompie has thought short and soft [as apposed to long & hard] on this one - only remedy I ever saw work was Oom Albert drilled two tiny smallish holes in the remaining stud ... then he took long nose pliers [daai een met die dunnnn bekkie] and he sprayed the stud with coke [and some hour later more coke and again .. then some spook pippi - the he applied teh pliers and the stud came out [
So Peter - without drilling, oompie has no other solution to this dilemma...
BUT i like the idea if sweating e rod onto it and try that way ... just dont &^$# the thread ek sê.

broken off bolat removal.JPG (25.62 KiB) Viewed 2178 times

[Peter Connan]

Oom Mac, that might just work if I can get in there with a drilling mashine, will have to wait and see.

I will obviously work as carefully as possible, but if the thread does sustain some damage it can still be fixed with a heli-coil (which in my opinion should almost be factory-fitted in any thread tapped into aluminium).

Perhaps I can modify Kobus's idea by cutting a slot across the top with a small cutting disk on the Dremel?

[Grootseun]

Peter , ekt n paar uitgehaal in verlede en al is dit n k...k job moet ek se al wat ek ooit gelry het werk was on of n stukkie rod of bout aan hom vas te weld , die hitte maak ook hom los anders daai twee gat idee van Oom Mac is n wenner as jy plek het , ook het ek al n gat ingeboor en getap op n kleineer bout groote dan n kleiner boutjie ingedraai en hom liggies vas getackweld en uitgedraai soos soetkoek

ekt natuurlik altyd al my karre waarmee ek gespeel het se exhaust studs vervang met gewone mildsteel boute - hy boor darem aansienlik makliker uit en vir een of ander rede het ek gevind dat hulle nie so gereeld afbreek nie

Dis my

[Peter Connan]

Driko, dis nie moeilik om te verstaan hoekom nie: Die hitte maak dat die uitlaat-spruitstuk rek en krimp.

En high tensile hou nie van hierdie rek en krimp besigheid nie, dit maak hom bros.

[Grootseun]

Maak sin Peter , ek moet dit seker geweet het ( die rek en krimp storie ) maar ekt gister my uitnodiging vir April se Worlds Naturual Strongest Man in Australie ontvang so my gymsessie gisteraand het my brein gerek en gekrimp

[Peter Connan]

Geluk man, ek hoop jy doen ongelooflik goed.

Jy is welkom om my Patrol te leen vir "bench presses"