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Not sure if I have enough stud to weld anything too.
You do. I weld on studs that are broken off 1/4" down in the hole. If it's "too short", just build it up with your weld "pile" until you're satisfied with the height...then blast the hell out of it while welding your nut onto it.
I'd think a typical propane torch would be sufficient heat to get that stud out though....but know that you need to keep the heat focused on the aluminum housing, surrounding the stud, all the while that you're trying to remove the stud. The aluminum moves heat so fast that if you remove your heat source, it'll cool way too rapidly. Have someone hold the torch, through the t-stat hole, right on the part of the casting that the stud is threaded into. While they're holding the torch there, work the stud back and forth, then thread it out.
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Last edited by Tom400CFI; Apr 12, 2021 at 11:45 PM.
The drama continues. I hired a pro and all he was able to do was remove the little nub while trying to remove the bolt. Said he didn't want to go any further as he was afraid of damaging the aluminum intake. Didn't charge me anything though I offered to pay him for his time. He contacted a guy that could possibly reverse drill it out. Talked to him but he wasn't really enthused about making house calls and yada, yada. Tired of dealing with it for the time being. Going to call some other mobile welders and see what they think. Ready to grab some bits and endmills from work and just go at it. Thanks everyone.
sometimes the last resort is drilling it out. it just sux. you could probably find a replacement intake manifold for real cheap!!! dime a dozen. but a major pita, obviously.
Ok I have a nice pilot hole completely through. Felt it come through the bottom. Should I tap this out for a 1/4-20 or continue enlarging and try to easy out it? I have everything to do whatever. Here's a picture.
TIA
Joe K
No ones fault but my own. I took my time but just went one little turn too far. It's was done too. Had more than enough thread. Though I have been, as they say no use crying over spilled milk. Thanks again everyone.
Checked out intakes on ebay. Hope I don't have to go there. Just bought some Bosch cobalt drills. 1/8, 1/4 and 5/16. About $12. Going to give those a shot. Be here Saturday so it will be sometime next week before I can get to it.
Checked out intakes on ebay. Hope I don't have to go there. Just bought some Bosch cobalt drills. 1/8, 1/4 and 5/16. About $12. Going to give those a shot. Be here Saturday so it will be sometime next week before I can get to it.
Joe K
Take the manifold off and see if there is a machine shop in your area that can EDM it.
Checked out intakes on ebay. Hope I don't have to go there. Just bought some Bosch cobalt drills. 1/8, 1/4 and 5/16. About $12. Going to give those a shot. Be here Saturday so it will be sometime next week before I can get to it.
Joe K
I've got an extra manifold lying around out of an 86 as well if you end up needing one.
Sorry for your frustration. 
