removing stuck stud..

[87-325ic]

they make them this small?

is it not easier to just drill the whole thing out, and re-thread it with a helicoil or time-sert?

i doubt an easy out will turn this thing since its broken twice on me now.

[!kid]

a tig welder will get that bad boy right out

[87-325ic]

too bad i dont have a tig welder.

[AndrewBird]

I've had luck using a drill just slightly smaller than the bolt, drilling it out, then using a punch to collapse the bolt in on itself and pull it out. On something this small, it might be hard, but it's worth a shot. If all else fails, drill it out and helicoil it.

[87-325ic]

If all else fails, drill it out and helicoil it.

It's all failed. How do i best go about drilling the whore out?

Take the head off, and take it somewhere and pay the cost?

or get creative and do it on my own? got any suggestions for not ruining the head and doing it in place?

...

[tinkerputzer]

Been there done that, only difference was it was the valve cover stud under the intake. You are lucky for the accessibility you have. Don't waste you time with screw extractors, if you snap that off then you are truly fucked because you can't drill through that. You will have to drill it out. Best way is to work your way up in size until you have reached a drill bit which is slightly smaller in diameter then the stud itself. Once you are that far what remains of the stud should either collapse or back out. Good luck.

[87-325ic]

thanks...


now.. as for the drilling .. should i take the head off, or should i attempt it in place, by maybe making some sort of jig or something?1

[jlevie]

If you are worried about the drill running out into the casting. Slap the valve cover back on and take the car to a shop and let them deal with it. The cost to have them extract the stud will less than the cost to replace the head.

[tinkerputzer]

thanks...


now.. as for the drilling .. should i take the head off, or should i attempt it in place, by maybe making some sort of jig or something?1

I'd do it in place.

[Hick]

shotgun or sawsall

[gazellebeigem3]

^coolpoints for using both

[87-325ic]

:)

ITS OFF!!!!! i drilled that bitch out this morning. managed to get the threads out of the first few mm's then ran an M6x1.00 (same threads as the stud) tap into it carefully, it cut new ones and removed some old ones.. It takes a bolt now. BTW, i used 30mm bolts with washers instead of the studs, mostly because i couldnt find any more studs local.

I was prepared with a drill,tap and bolt the next size up if i needed, but didnt!

WHAT I LEARNED!!!---->>>
DO NOT use loctite anywhere near the head, or aluminum for that matter.
when removing a stuck bolt or stud: flatten the head.. Center punch the Center.
Start with a very small drill bit, like 1/8th" or less, and drill straight and centered a little at a time., then step up the next size, drill a little further, and then the next size up until you are at the correct depth and width.
Keep it centered and straight.
Preferably use left handed drill bits.
then tap and use the next size bolt or an insert.
And, Be Clean, mask off the area. dont spend the rest of the day with Qtips and a tiny vacuum detail tip.

The car runs Sooo much better now that the huge leak is fixed. it idles smooth, doesnt drop or move at all, and just pulls smoother and stronger.

now i need to fix my exhaust leaks.. cheap headers!!@


Success!!