this is driving me mental... after 1.5 yrs of my FD being down..

it's finally so close to completion... everything fully assembled and ready to be dropped in

but then the **** studs decided to throw a monkey wrench in the works...

all i wanted to do was put on my aftermarket


first i had 3 downpipe studs break on me... so i removed the turbo's and exhaust manifold.. took them to the work shop.. while i was at it, i had it Converted to TTC and ported the wastegate.. and fixed the studs..


so i come back.. all ready to put it back.. and guess what? the god damn stud on the front housing breaks off...


i get a T bar welded to the remainder of the stud... heat up the housing, liquid wrench.. u name it

eventually the stud breaks off flush with the housing

FAWKKKKKK


so now my only option is drilling this bastard out...


can it be done at home with a pistol drill? or do i need a Drill press?


if i Punch the stud to make an indentation.. and the hit it with a carbide tip will it work?

I'm afriad the drill will jump around and chew the aluminum or something...


do u start with a really thin one and gradually work ur way up?


details please!

 

going to be hard to get a drill in there...and if you do...really can't see what your doing...
if you have a welder...you can try to build the stud up....weld a nut on to the part you built up and get another shot at getting it out...
again not sure how far the stud broke off inside...(you don't want to F"up the threads in the hole)
good luck....my top right hole got stripped out yesterday...

brad

 

going through the same ordeal right now. mine is back today from the machine shop and should be running by tonight I hope!

Trev

 

i tried building up weld.. didn't work.. it just shears off again...


the problem is teh entire long block is assembled with manifolds and harness the tranny, engine moutns and everything else.. minus the twins..


just one BLOODY STUD!

RAAARRRR

 

I'd be surprised if you had enough room to do any real work on it without lifting the engine. It always a good idea to replace studs/bolts on the turbo and exhaust side during an engine R&R unless you know they are low mileage or recently replaced.

 

mahjik...the engine is on the ground already

i figured while it was out.. i'd remove the stock Downpipe and replace it with a performance one i had.. rather than trying to change it in the car later down the road...

it was then that whole disaster started... if i had just dropped it in the car and left it alone i'd be driving it now

the DP bolts breaking... and eventually bringing me to this point

 

Ah, if it's out of the car, then the oil issue becomes if you have the tools to take it out. Honestly, if you have a truck, I would take it to a machine shop and let them get it out. Less chance of messing up anything else as they'll have to right tools for the job.