So I was replacing a stripped exhaust stud and ended up cutting it flush to drill a hole to use a #5 screw extractor. As it turns out the extractor broke off into the stud. I have been un able to get it out. I have ruined 3 good drill bits trying to drill small relief holes around the extractor piece, and have pretty much boogered the outer rim of the original stud hole. The tool is hardened and I cannot find a drill bit to bite into the piece. Even ruined a tungsten carbide bit for my dremel trying to grind it out.

Can I run with only 3 studs properly torqued down? Any other suggestions for removing the broken piece without damaging the original hole further??

I have a helicoil set ready to fix the hole but I can't get that mother freakin piece out. My biggest fear is that it is too far gone and the housing will need replacing and thus a rebuild.

 

that sucks man. did you try heating it before you tried to remove it with the extractor?

I'm gonna search around and see what i can find out for you but you should try the same as I have seen this topic before. Do you have pics of what we're dealing with?

Are you able to drill out the stud around the tool? idk i'll be back in a bit

 

you just gotta drill it out. It will take forever. Then use a a tap and a thread-sert. Not helicoil. Thread-serts are bigger than helicoil. Oh yeah, and extracters almost always break off. I have never had one work.

 

okay man try this, if you have a welder you might be able to build up the broken stud w/ weld and then weld a nut on the new metal.

Or just drill that sum bitch out and retap or helicoil or whatever.

The welding thing is cool though cause the weld should stick to the bolt but not the aluminum housing.

Any one else got any ideas?

 

the welding thing works sometimes. The best thing it does is get the piece extra hot which makes it easier to get out. I have replaced lots of broken head studs on porsche cases and heat is the best because of the rapid expansion rate of aluminum and the not-so-rapid expansion rate of steel.

 

The remnance of the tip of the tool is about middle-right of the "hole".

 

+1 for trying to get some weld on it. If you can then weld a nut to it, it should come out. Definitely use a thread sert. It's far superior to helicoil.

 

Before getting someone to weld down in the engine bay, try and break the tap. Its hardend and cuts well, but it is brittle and will break if you hit it. Once you have broken off some of it, that will give you some relieve and then maybe it wil come out.

Good luck.

 

I think these methods have been failing because of the subject: rotary exhaust grade iron/steel. That crap is tough. It will give you trouble, there are no two ways about it. Best of luck to you.