exhaust stud broke and another drilled out..

[putang29]

So I picked up this rb25 for super cheap and need some advice as far as the broken exhaust stud and 1 other issue. There were 2 studs broken, and the previous owner had used a drimmel or something to drill around one of them and get it out. Now there is a huge hole where the stud used to be. The other stud is still in the head and I turned it into a machine shop to fix. Now the machinist is saying he cant extract the stud and he will have to drill around it. My first thoughts were ok, fine, just sleeve the stud area and tap/die the threads in the sleeve. Now I dont know what to think. The last word I gave to the guy was ok lets do it and get it over with. Any thoughts?

[l0nestar]

I don't see why you can't extract the recessed stud, unless it had a bit broke off in it.

I have had to replace broken and recessed exhaust studs before. if the head/ engine is not in the chassis, it's a lot easier to work on.

Are you talking about re-filling the area, or boring it out and using something like a Heli-Coil? I would assume that a Heli-coil would be easier than re-tapping for a larger stud.

Sounds like you should be looking for another head, just in case. it may be cheaper than repairing this one.

[legit240sx]

For the stud that is not drilled out,
get the machine shop to weld a nut on the end of the stud then get a wrench or impact and start turning. If the bolt is recessed in the head, try to build up the end of the stud using tack welds. Then weld a washer to the end of the tack welds then a nut on to the washer. The heat of the weld tends to loosen the stud up. Also, some sort of bolt penitrent would help but do it before welding and let it sit (might want to clean it off too before you weld)

[TheRBguy]

I had the two outside studs broke on my Rb25 when i got it and they were broke off clear in the head, i drilled them and pounded an easy out in them and they turned right out with no difficulties what so ever, they were not even that tight.

[Largekid]

I had the very rear top one break on me. I towed the car to the shop and welded a nut and washer on it and backed it out easily. You should be able to build up some weld if its broke even and do the same.

[StricNyne]

ughh this is why SS or ARP exhaust studs kick a** (also cost an assload) i want to do them on mine, i am thinking of helicoiling all threads so they are stronger, and using smaller arp studs

[putang29]

I went n got the heads from the shop n gona drop em off at a welder this afternoon. About the one stud that was drilled out, what is the best approach for filling in the drilled area and sleeving it for new threads? Thanks for the help all

[putang29]

So I took it to a welder and he said he can probably fix the drilled out area and do the weld a nut to the stud deal. All in all, however, its gona run me about 175 bucks wtf...

[putang29]

problem solved. got a good welder to fix it for 120 bucks and looks good. thanks for the input on this i know this s*** gets old lol