Help! How to remove broken header stud bolts??

[97scoob]

Somebody help me please?!?!?!?!?
i just pulled my motor to replace my clutch, and i had to take the headers off, but the studs and nuts holding them in fused together, so i had to take them off like a bolt, but when i did three of them snapped all on the same side! i have tried literally everything i can think of (easy out, tried grabbing onto them with vise grips, drilling them out and retapping but that took forever and didn't even get far), so now i think i am basically screwed. i am having a mechanic help me tomorrow, but if we cant get them out, i am going to have to get new heads :( can anyone think of another way to get them out, or is there anyone with some heads around that i could do a local pick up like tomorrow? :) here is a pic of the head
https://sl-i.net/FORUM/images/imported/2008/11/1121082236-1.jpg
i know it looks like there are huge gashes in the head, but really they are tiny scratches, just the flash reflected off them.
thanks

[decke48]

heat (oxy/ast or map)and a spray bottle of water. basicly heat the surounding metal but be careful you dont melt the aluminum then spray with the bottle of water till it cools down then try the easy outs again. this is a trick to get frozen bleeder out. should work for this to.. and do you have a 2.2 or 2.5 because i might be able to help if you cant get them out :wink:

[97scoob]

i have a 2.5, and thanks i will try that. i already have a mechanic here helping me though and will have 2 here soon :roll: but thanks for the offer.

[Huffer]

Jake - you're kind of new here so I'm going to go easy on you... :)

When creating a thread, please try to use a SUBJECT that is appropriate to the question or content.

I have edited your thread title from "HHHHHHEEEEELLLLLLLPPPPP!!!!!!" which makes no sense if someone is searching, to "Help! How to remove broken header stud bolts??"

Thanks!

[Zedhead]

IMO, Hold off on the heat.

Do a search for Drill-Out. Sears sells a knock off of this tool.

Left handed drill bit will sometimes to the trick.

Next time make sure you have some Kroil on hand, and You won't have this problem. www.kanolabs.com (http://www.kanolabs.com)

[97scoob]

-okay huffer, i will do that next time.

and as an update, after 5 more hours of drilling, heating, cooling, and getting very annoyed, i have taken the head off, and will be taking it to a machine shop so they can do it properly. those things are cemented in! so now i have to wait until monday, take the head to a machine shop that i am connected with (thank god) and i should get it back by wednesday, then put it back on. And, this is going to cost me way more than i thought!!, because now i have to buy a new head gasket, intake manifold gasket, pay for the machining, and to top it all off, while i was taking the head off i had to take the timing belt off, and i realized that i need a new timing belt too :-(

IMO, Hold off on the heat.
Do a search for Drill-Out. Sears sells a knock off of this tool.
Left handed drill bit will sometimes to the trick.
Next time make sure you have some Kroil on hand, and You won't have this problem. http://www.kanolabs.com
i tried drill out, and a left handed drill bit but neither worked. also, i soaked them in silikroil, and PB blaster before i tried to take them out, but they still broke.

[Zedhead]

Dman, thems some stubborn SOB's.

That is the first time I've ever heard Kroil, or Drill Outs not working.

Did You put the Kroil on before the nuts came off? Next time, get an impact on them and TIGHTEN them a little first, them loosen. It'll knock the threads loose going up, towards the clean threads.

There is one trick left. And it takes some mad welding skill. You can buy a large gage welding rod, and quickly weld it on the stud. You have to make sure You hit the stud, and NOT the threads on the head. Usually, then You can get them to turn.
You might want to search the Yellow Pages. Lots of cities have dudes that are mobile. They'll come right to You garage and get the stud/bolt/screw out.

It could have saved You from pulling the head?

http://www.hobartwelders.com/weldtalk/s ... hp?t=14860 (http://www.hobartwelders.com/weldtalk/showthread.php?t=14860)

[Huffer]

Something else you can do, is just drill out the entire bolt and make the hole bigger, install a new stud...?

[Zedhead]

Be very careful drilling al heads. It's easy to get to close to a water jacket. I'm sure there's some harmonic stressing going on this close to the exhaust port. You don't want the head cracking 5k miles down the road.

If the machine shop mentions this option. Make sure You have the provisions to drill the exhaust pipe flange for the larger stud.

[decke48]

btw my offer still stands
https://sl-i.net/FORUM/images/imported/2008/11/S1050530-1.jpg
:smt023
trade or your head. and some minor cash for me pulling out the studs

Edit i forgot sandown was more east then i thought. but if you need the head/s we can make some arangements

[97scoob]

Something else you can do, is just drill out the entire bolt and make the hole bigger, install a new stud...?this is what i will be doing, but as rob said it is a pretty delicate procedure, and i dont want to go f'ing my head up, so i am just going to bring it to a machine shop and have them do it. i wont have to use a bigger stud though, i can use a helicoil, and use the same stud:
https://sl-i.net/FORUM/images/imported/2008/11/Sell_Helicoil_Screw_Thread_Inserts-1.jpg
and hopefully this little gadget should do the trick. if not... well i guess i get a new head.
and thanks again decke, and i will keep your offer in mind. :wink:

[SUBBIEEDUDE!]

yah thats what my dad told me u should do. ahaha when he saw it. ahaha

[97scoob]

well, i got the head back, and the machine shop got the studs out, and i put everything back together, but now my car is running wicked rough, not misfiring, just really rough.
so my problems seem to be neverending.
https://sl-i.net/FORUM/viewtopic.php?f=11&t=12000