Exhaust manifold stud removal...how do I do it?
Thread Starter
Instructor
Joined: Sep 2001
Posts: 129
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From: North Central TENNESSEE
Exhaust manifold stud removal...how do I do it?
When I put the under car chambered exhaust on my 67 Corvette SB, one of the studs broke off the exhaust manifold. I know I will have to drill it out, but does anyone have any advice on how to do this? I will probably use an air drill and metal bits. Do I remove the manifold or drill while it's installed? How do I avoid damaging the manifold and threads?
Thanks for any help,
Alex :chevy
Thanks for any help,
Alex :chevy
Race Director
Joined: Apr 1999
Posts: 10,866
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From: Beverly Hills/Pine Ridge Florida
Re: Exhaust manifold stud removal...how do I do it? (Alex in Germany)
I think the best way is to remove the manifold, then heat the "ear" of the manifold with an acetylene torch. Heat it cherry red. If any of the broken stud remains sticking out, grab it with a vice grip and start "wiggling". You can usually get them out that way. TOUGH to drill dead center, and then re-tap the hole in my opinion....tough to do anything with the manifold on the car. Chuck
Burning Brakes
Joined: Apr 2001
Posts: 889
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From: Victoria BC
Re: Exhaust manifold stud removal...how do I do it? (Alex in Germany)
Is there anything left of the stud. If so you can weld a nut on to the left overs and take it out that way, the heat from the the wleding helps break it free also. Other wise I would grind the stud down and make it flat and then punch a starter hole and then start drilling. I usually drill it in three or four goes with differant size bits.
Drifting
Joined: Aug 2000
Posts: 1,805
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From: Annapolis MD
Re: Exhaust manifold stud removal...how do I do it? (Alex in Germany)
I've read that if there is stud remaining above the flange you can heat it and remove with a cutting torch without hurting the threads. I'd think it takes some experience though.
The fool-proof method is take it to someone with a mill and they can remove the stud as the mill won't allow any creep like a hand drill or drill press.
Another method would be to make a jig block (piece of steel with a couple holes in it, index on any other studs that are still ok) that is thick enough to hold the stud sticking out plus some. Secure it to the flange and let it act as a guide to drill the rest of the way through the stud.
None of these are much fun.
-Greg
The fool-proof method is take it to someone with a mill and they can remove the stud as the mill won't allow any creep like a hand drill or drill press.
Another method would be to make a jig block (piece of steel with a couple holes in it, index on any other studs that are still ok) that is thick enough to hold the stud sticking out plus some. Secure it to the flange and let it act as a guide to drill the rest of the way through the stud.
None of these are much fun.
-Greg
