Exhaust studs

When stripping down I found one of the exhaust studs had been replaced with a set screw.
Needles to say it would not undo so I had to cut it off

So I now need to cut it flush with the engine block, drill and tap it.

What adivce can you give me before I start. Such as treads and anyone know if I can get an off the self replacement? (Not looked for one yet)

Prob an easy job but never done something like this myself

Cheers

 

You'll get several different pieces of advice about this. The one thing I think we all will agree on is that you want to avoid cutting it flush and drilling as long as there is anything to grab.

My advice is to heat the boss that holds the offending hardware (set screw??) with a small welding tip (#3 tip on this side of the pond). Keep the flame moving so you don't overheat a spot and sag the aluminum. Then extract the fastener with a pair of locking pliers.

 

as above, while there is still a chance of removal without drilling go with that. Used a blow torch on mine and then once nice and hot some instant freeze(plumbing supplies) directly on the stud. Might take more than one attempt and use a rocking type movement to try and free it. I found that the first half centimetre was the offending bit and some time a light tapping from side to side will help free it. Also if you have the time a real good soaking with plus gas or similar, at least overnight will help.

 

Agree. Try to remove it BEFORE going the cutting/drilling/easy out route.
Another option is a stud remover with a breaker bar. The Craftsman model is about $25 from Sears.

 

IF you have to resort to drilling out the stud in the end & you mess up the threads you can drill a slightly larger hole, retap & use a Helicoil insert.

I have had to do that many times over the years.

 

Thanks for the advice.

I will try heating up first and see how I get on

As allways this site is a wealth of great advice and information

THanks

 

Heating the stud with a torch and then applying an unlit candle can often remove a stuck bolt without damage. The wax wicks up the threads and acts as a lubricant. This works on the REALLY stuck bolts. When you try to take the bolt out clamp onto it with vice-grip pliers and loosen a smidgen and then TIGHTEN it up a smidgen. Work it back and forth as many times as you need to but remove the pliers when heating and use plenty of wax.
TECHLINETOM

 

i broke a stud on my 81 xj650 i was wondering are the studs pressed or threaded into the block

 

Farmington Hills MI?

They are threaded in.

 

I've had some luck heating the fragment and brushing-on vegetable oil.
It's and old trick.
It has a high flash point and "Runs" (capillary action) to surround the threads.

Soldering Flux if the angle is too steep to get the oil on it.

My favorite way to tackle the problem:

Wrap it in a towel and put it on the floor of the car.
Take it for a ride to the areas BEST Technical High School.
Plead your case to the Teaching Instructor in the Machine Shop Building.

Ask for their help.
Don't forget to beg!

When they hand you your Head back with all the Holes nice and clean and retapped and oiled ...
Make a "Donation" to their "Shop Expendables Fund"

You will love them because of the big money you save.
They will love you because you will make their week giving them a good reason to be pros and work a project on a real world item instead of a junk project that's in there for practice.

 

yes micarl i am from farmington hills mi