Hey guys was installing my exhaust manifold and noticed one of the studs was shorter. The top left stud was grinded down. I had my motor rebuild and i think the builder was unable to remove it and maybe damaged it.
was unable to bolt the screw on it so decided to remove it.
the two screw method did not work and twisted in half 😔


Whats my best options now. I only have a blue torch but that didnt work. Might need to buy the yellow MAP torch too help heat it up.
I started to drill the middle. Maybe an extractor will help.
Or should I borrow a welder and weld a nut on it to remove it?
any had a simillar issue?
wish I had an inductor heater but their pricey for just a one time thing

 

Okay guys I had a budy try to weld a bolt on to the stud and no matter how many times we tried it would fall off. This stud material is so hard to weld on to.
im gonna have too drill this out with a carbide bur tool.

 

Center drill and something like an easy-out might work, otherwise, grind/file flat, center punch, and then slowly drill down center with progressively large bits until you get close to tap size, and then clean threads with a tap.

Had to do something similar with my Miata turbo, where the stud had broken, and then I drilled it until the stud was so thin, I was able to bend it in on itself inside the hole and pull it out, and retread at the end.

 

what size fix a thread would I need? Is this a m14? This thing is really stuck on there. Gonna have to tap and helicoul to dix this

 

The stud size is M10x1.5mm by 48.9mm long (https://www.atkinsrotary.com/74-92-R...39-10-105.html). You should have used a stud extractor to begin with, rather than the double nut method, otherwise you might not have been in this predicament. If you choose to use an ez-out, don't snap it, otherwise you fu¢ked. Seriously, I would just take the block to a reputable machine shop and have them remove the broken stud.

 

I tried welding a nut on it many times and it just wong stick to it. I gave up on the welder. Just gonna use a burr to grind it out as much as I can. I tried to us a ez out and broke on me too. Now im fighting to get the extractor piece out.

 

Did you heat the broken stud with MAP gas and then try welding. What type of welder are you using? Try using a nut that fits the stud and only put it on halfway before welding.

 

grind using a ball file, in a way where if it catches it goes "up" away from the hole so you wont mess up sealing.

Is steel so slowly, otherwise you will heat it and work harden it. Use as small of a file to try to grind as much of the easy out as possible and then center drill, again, slow with lots of pressure behind it cause steel, some cooling fluid if possible