1. Some members were not receiving emails sent from XJbikes.com. For example: "Forgot your password?" function to reset your password would not send email to some members. I believe this has been resolved now. Please use "Contact Us" form (see page footer link) if you still have email issues. SnoSheriff

    Hello Guest. You have limited privileges and you can't "SEARCH" the forums. Please "Log In" or "Sign Up" for additional functionality. Click HERE to proceed.

Broken manifold stud removal

Discussion in 'XJ Technical Chat' started by mlew, Apr 7, 2015.

  1. mlew

    mlew Well-Known Member

    Messages:
    3,090
    Likes Received:
    241
    Trophy Points:
    63
    Location:
    Apex, NC
    Been working on rebuilding a XJ11 this week. Just finished installing the cylinder head after new guide seals and a valvel lap. I was putting the first carb boots on and the screw got a little tight. Tried to loosen it up and the head snapped off. I still had about a 1/2 inch of bolt there so I weld a nut onto the stud . Well it broke also leaving me with only about 1/4 inch. I'm going to have to drill this one out.

    The biggest problem drilling a broken is keeping the drill centered. I thought about it for a while I had the bright idea to make a drill guide to help. A few minutes with my benchtop lathe and I had a guide. It is threaded on one end to screw onto the old piece and centered bored to keep the drill straight. I was amazed how well this worked. The hole is perfectly centered.

    I still have more work to finish getting the stud out but this was a great start.
     

    Attached Files:

    Door dude likes this.
  2. jayrodoh

    jayrodoh YimYam

    Messages:
    2,573
    Likes Received:
    1,144
    Trophy Points:
    113
    Location:
    Cleveland
    That's awesome, wish I had that a few weeks ago. I also welded and ended up still breaking off close to the head. I bought one of those long multihole drill guides, works well but the long shape makes it awkward in some situations.
     
  3. Door dude

    Door dude Active Member Premium Member

    Messages:
    458
    Likes Received:
    91
    Trophy Points:
    28
    Location:
    Mountain Home Arkansas
    MLEW, what are the dimensions of that thing ?
     
  4. mlew

    mlew Well-Known Member

    Messages:
    3,090
    Likes Received:
    241
    Trophy Points:
    63
    Location:
    Apex, NC
    1/2 round rod with a 1/8 pilot hole. Other end was tapped to fit the stud. After screwing it on the broken stud I drilled 9/64 then 5/32 and so on until the guide fell off. Then drilled for a thread insert. It kept the hole centered nicely.
     
  5. Jdig9320

    Jdig9320 New Member

    Messages:
    14
    Likes Received:
    0
    Trophy Points:
    1
    Location:
    Jasper, Alabama
    Did you have to re-tap?
     
  6. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

    Messages:
    19,647
    Likes Received:
    6,755
    Trophy Points:
    113
    Location:
    The City of Seven Hills
     
  7. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

    Messages:
    19,647
    Likes Received:
    6,755
    Trophy Points:
    113
    Location:
    The City of Seven Hills
    If you have a set of metric drills you can carefully drill out to the minimum diameter of the threads on the fastener, and pick put the rest of the fastener's threads with dental tools. That only works if the threads have not become hopelessly coroded to the head.
     
  8. Jdig9320

    Jdig9320 New Member

    Messages:
    14
    Likes Received:
    0
    Trophy Points:
    1
    Location:
    Jasper, Alabama
    Mine are superdidooper corroded. That's why I was asking. To see how the process went for this bike
     
  9. Door dude

    Door dude Active Member Premium Member

    Messages:
    458
    Likes Received:
    91
    Trophy Points:
    28
    Location:
    Mountain Home Arkansas
    Did you try to easy-out the bolt after you drilled with a 5/32 ?
     

Share This Page