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Has anyone snapped the stud that attaches the downpipes to the head?

Decided to take down pipes off to do some paint work, but as i removed the exhaust nuts *snap* off came the nut with a broken stud left behind.

Ive tried everything i can think of - cutting a slot for a screw driver/using a reverse thread drill/using bolts extractors/blow torch/drilling a hole and using broken screw removal tools.

Anyone know what else i can do?

Here's the offending stud:

Depending on how much visible stud is left, you could try welding something onto it to give you some purchase - I've seen that done successfully a few times.

pete

milleplod wrote:Depending on how much visible stud is left, you could try welding something onto it to give you some purchase - I've seen that done successfully a few times.

pete

thanks for the idea, see the pics ive attached to my original post

Been done and discussed before, I'm sure. Search for "stud" (on here, not Google ).

But - as suggested, clean the stud and try welding a nut over the top of it?

(I'd disconnect the engine ECU first)

Al

And when it's all done - use Brass or phosphur bronze nuts so it doesn't happen again.

Dread that happening - been lucky with the studs on the 12s - they came off no probs and I've got some extreme temperature grease to go on the studs and will loosen them off fairly regularly to make sure they stay like that. Now the 11s, extreme heat on them this week and fingers crossed

Also, shove some kitchen towel/paper or clean rag onto that great big hole soonish as well.

f90x wrote:Also, shove some kitchen towel/paper or clean rag onto that great big hole soonish as well.

will replace a.s.a.p took it out to use blowtorch on it.

i dont have access to welding equipment so cant do the welded on bolt trick, as that seems the most successful.

decided to get a 'stud extractor' off ebay, ill see how that goes when it arrives....

ebay tool: http://www.ebay.co.uk/itm/391371905094? ... EBIDX%3AIT

Have you given it a good couple of whacks with a hammer as well?! It sometimes 'shocks' the corroded-together parts into......well, parting!

Pete

milleplod wrote:Have you given it a good couple of whacks with a hammer as well?! It sometimes 'shocks' the corroded-together parts into......well, parting!

Pete

High freq vibration is more effective, I've found. If you weld a nut to the stud, then soak the stud at the entry to the head with proper penetrating oil (on a kitchen towel - over night)

Then apply some gentle heat to the area (hot air stripper) and use a hammer drill with a socket on the nut.

Al

taking it all on board,

ive hit it with a hammer, will a bigger one help?

need to look at the welding option, need to find a friend with 'portable' welding equipment, otherwise i think it will be finding engineering place that can do the work

Good luck - keeps us posted

SyRexx wrote:Anyone know what else i can do?

I like this idea in an older thread , no sure if your stud is too badly damaged though
http://www.boxertrix.com/phpBB2/viewtop ... c&start=15

I think for future exhaust removal- I might be inclined to Dremel a slice down two faces of the nut and remove the nut in pieces - leaving the stud intact.

+1 for that Al, did that with the manifold studs on my MR2, so much easier.

Al.