1) exhaust stud gets seized 2) use double nut method to remove 3) sheer off stud 4) weld a nut to what is left of the stud 5) nut snaps off 6) repeat welded nut 3 times 7) fail 3 times 8) notch the broken stud 9) use a screwdriver to remove 10) doesn't work 11) buy easy outs from halfords 12) drill into stud then use easy out 13) snap off easy out inside the broken stud 14...........oh crap. So, does anyone have any idea how to get this stud and extractor out? Tried drilling with a masonry bit but im starting to damage the opening in the alloy head. Is this a head off job and if so anyone know where I can take it to in sw London/surrey? I was really hoping to get the engine back in the van before Volksworld :-(
I ended up centre punching the stud then drilling with progressively bigger bits until I could tap it. You can get oversize studs for this purpose. Just take your time and treat it as a challenge... I then used thread lock when screwing them in and coppaslip on the thread before fitting the exhaust. Yes it is a head off job..
I'd retry the welding method as about the only poss, after getting plenty of heat on the head. Unfortunately, thin screw extractors (as you've found) tend to snap off, leaving a bit of hardened metal in the stud, so you can't drill it.
Forget the nut - load of crap unless you can screw it right on. Weld on full power initially then down a notch in bursts to build up a mole-gripable blob. The heat will help.
Yeah get some heat into it to free it off as Zed said just built it up at the weld is tough as old boots. Don't worry to much about damaging the thread in the head as I had a stud pull out a few years back and I heli-coiled back to m8 and it has been fine.
I don't wait at all, grips on, a little pressure to and fro, gently does it. It may not move straight away, but keep a little pressure on, to and fro, to and fro and it'll crack eventually. To retain your patience, keep in mind what a hassle you'll have saved yourself when it screws out.
As per Zed, this happens all too often in the bike world, 2 min job turns into 2 hours. for what it is worth I have never had success with an easyout on a corroded stuck fastener and that horrible feeling of despair when it snaps is not good.
Welding didn't work. Manged to get a good blob and good grip with the mole grips but eventually the welded bit snapped. I've heard that carbide drill bits work? ...
IMO you will struggle trying to drill the easyout out cos it will be very hard but you have nothing to loose mate, if u got a good hot weld on it and it didn't move then it's looking like its going to be a pain tbh. What size easy snapped?
It's a problem getting a strong weld onto a stud with a hole and snapped extractor. Not sure what to suggest. If you can't sort it, the head will be scrap. Perhaps worth taking to an engine re-manufacturer and paying a few quid to have it removed and re-threaded with an insert?
I was making slow progress last night with a masonry drill but I think it will do more damage than good. I have already pitted the surface where the exhaust mates up with weld splatter. I'm at a bit of a loss as to where to take it now. I think you are right Zed, I need to whip the head off and take it to a local engineers to fix it for me. I wish I'd never used the sodding easy out as I could have just carefully drilled out the old stud and re cut a new thread. Here is a pic of how it looks now:
If you can find a company near you that does wire eroding they'll probably have a machine called a hole burner. They could burn that out in a jiffy.
That will prop clean up, at least if u get the head off either u or and machine shop can get it set up in a pillar drill and drill it nice and square with some good pressure. Hope it works out mate, shame to have to scrap a good head for one bad bolt.
Can't find any Erosion Wire places near me, they all seem to be up north. I'm hoping this engine reconditioning place can help me out. If all else fails, where would you guys look for a new head?
