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Old 01-06-2015, 05:28 AM   #1 (permalink)
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Talking Broken Exhaust stud repair

Broken exhaust stud repair.



I had a cylinder head come to the shop, it had a bad drilled exhaust stud.
Whoever tried to remove the broken stud before, did not do the best of jobs.
Part of the old stud was still in the hole. Along with part of an EZ out.




I took a die grinder with a carbide burr and ground out the stud and EZ out.
I was left with this for a hole., I knew a simple Heli-coil would not fix it.


So I made a bushing to repair it.

The head casting was dilled and tapped for a ˝ x 13.






Next I installed a set screw. You could also use the threaded part of a bolt.



Use “Green locktite”



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Old 01-06-2015, 05:29 AM   #2 (permalink)
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After about an hour, the locktite is set up. Drill the set screw .2660, then tap for 8mm x 1.25


Next fit the stud.



The customer should not have any exhaust alignment issues of the exhaust manifold now.
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Old 01-06-2015, 09:08 AM   #3 (permalink)
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So, you used the set screw like a time-sert?
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Old 01-06-2015, 09:20 AM   #4 (permalink)
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For all intentions.... Yes.
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Old 01-06-2015, 09:26 AM   #5 (permalink)
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I also use tons of anti-seize everywhere for this reason...

The nickel kind too.
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Last edited by Mr.Fodo; 01-06-2015 at 03:38 PM. Reason: spelled nickel wrong lol.
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Old 01-06-2015, 02:23 PM   #6 (permalink)
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Another great thread, with good info.
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Old 01-06-2015, 02:24 PM   #7 (permalink)
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I also use tons of anti-seize everywhere for this reason...

The nickle kind too.
agreed
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Old 01-06-2015, 03:08 PM   #8 (permalink)
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Good info.
I was lucky when mines broke and I had enough stud left to just grip it and unscrew it out.
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Old 01-06-2015, 04:03 PM   #9 (permalink)
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Got dang genius!! Fraction of the cost of a timesert also!
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Old 01-06-2015, 04:12 PM   #10 (permalink)
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What is different about the green loctite?
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Old 01-06-2015, 04:34 PM   #11 (permalink)
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What is different about the green loctite?
Green lock tight is a penetrating, sleeve retaining grade.

When you absolutely positively do not want it to come out.
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Old 01-06-2015, 04:55 PM   #12 (permalink)
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Old 01-06-2015, 05:36 PM   #13 (permalink)
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Ok Trans.... what am I supposed to see? the peened in bearing?
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Old 01-06-2015, 06:30 PM   #14 (permalink)
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Ok Trans.... what am I supposed to see? the peened in bearing?
Yup. That particular bearing likes to walk out, when it does it causes problems. Known solution is to stake the shit back in so it won't walk out again.
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Old 01-06-2015, 06:33 PM   #15 (permalink)
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Ok gotcha.....

Knurl the od of the bearing?

But if that is the fix rock on .... just not pretty.
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