Broken stud. Question?

[tokendog]

Ok, so apparently I do not know my own strength and I broke off a stud in the turbo elbow of my car while replacing the old stud. It had gone in relatively smooth until the very end - where it got a good bit tougher, and I tried to manhandle it...and that got me nothing but bad results.

The stud twisted right off inside of the turbo elbow and is flush with the part that means the downpipe on the exhaust.

Of course the turbo/turboelbow is off of the car right now, but I was aiming to get my car back up and running tomorrow.

Whats the best way of going about removing a broken stud? Drill a hole through the middle or just drill a new hole? If I go that route, what tools will I need and where's the best place to get them?

Also, if its worse than that, and I just want to get the car running right now...as in putting the manifold/turbo/turboelbow on the car, etc. and cranking it up, is there any thing that would make that a bad idea? I'm not looking to drive it, just want to crank it up and make sure its working right, and then I will turn it back off.

I assume this ok? I even assume I could, if I wanted, drive it without the downpipe hooked up, as this would be like running the car without exhaust, but what other issues/problems might this cause and why would this be a bad idea?

Thanks in advance. I am so pissed at myself right now and I knew better than to try to force it, but it happened and I live and learn.

EDIT: I just learned how to search again (sarcasm. I was too irritated earlier to search, so I just posted but then calmed, and searched) and found out about easy-outs. I will try this tomorrow.

However I was wondering about the other questions I had...
Modified by tokendog at 11:21 PM 10/2/2008

[Kalypso]

photos courtesy of the lumberjack: "flatblackian"

most of your post was filler, keep it exact and short.

spray some wd-40 on it and





you can get that bit at autozone or home depot.
Modified by Kalypso123 at 11:54 AM 10/3/2008

[CSUPUEBLOTIM]

Ya easy out bits are your friend. Goodluck!

[ArcherV20]

I'm so glad I didn't have to deal with this crap when removing my manifold.

[Kalypso]

it wasnt so bad once I did it once.

but I still worry whenever Im torquing a bolt that im not over doing it and stripping the tread.

[480sx]

Using a drill with an easy out is retarded and can cause a catastrophe. Easy outs can and will break if the stud doesnt want to come out. If an easy out breaks inside your stud you will be taking your head off and sending it to a machine shop.

Use the easy out with a hand tool, it looks like a T with an arbor on it kinda like a drill chuck.

[snake240]

ive used easy outs many o time. they work great but take your time worst case drill it out completely and get a tap and die set and make a new threaded hole.

[tercel drifter]

easy out is the key to your problem, bolts and studs brake so much it could be a trade lol

[tokendog]

Ok well, the easy out failed. I took it slowly and increased size as I went but to no avail.

Its on the O2 elbow housing going to the downpipe. Which is cast iron, right?

Also, a friend of mine who works in the auto world, recommended an idea I wanted to bounce off of you guys. He said a lot of mechanics do this and if I needed to get the car on the road as soon as possible, this would work.

He asked if the hole that the stud goes in to goes straight through the elbow and yes, it does. He then said to take a nut and a lock washer and put it on the other end and get a new stud. Drill out the broken bolt and make the hole clean. Then thread a longer stud through the hole and in to the nut and washer on the other side. I can then put the pieces together and when I tighten the nut on the other side, it will torque against the nut/washer combo and work just fine.

Does this sound like it will work? If it does, I'll do this and just purchase a new O2 housing elbow in the next few weeks. I just need to drive this car about 5 miles to get it inspected so that it will not be towed off.What do you guys think?

Thanks!

[tokendog]

bump. no one knows?

[CSUPUEBLOTIM]

Go for...worse that could happen is it not work and then you can't say you didn't try and just wait to order a new one.