Broken stud removal.

[Doctor J]

As I planned one week ago today I pulled out the broken portion of the exhaust manifold stud of the cylinder head.
I used cordless drill, 7/32 bit (5mm is better) for a pilot hole and drilling bushing with 10.5 mm O.D.(I machined it) 20 mm long to guide bit
To pull the stud out, I used Bosch made easy-out with 1/4 inch square shank, on which I placed the female end of 1/4 inch extension 10 inches long. Other end of extension went into adjustable tap wrench with which I unscrewwd the piece. It came out of the stud hole. The dept of the drilled hole must be about 2.5 drill bit diameters.

[stricular]

Noice work. COuld you elaborate about the "bushing" system you made up?

[HomeGrown]

I believe Doc made a bushing that fit the I.D. of the manifold bolt hole (10.5 mm dia.). He then presumably drilled a 7/32 dia. hole thru the bushing, to guide the drill. This makes it possible to drill relatively closely into the center of the broken off stud. Without a bushing guide, the drill would more than likely wander to the edge of the hole and destroy the original threads in the head.

[Doctor J]

That's right.

[stricular]

so the stud actually broke off deep inside tho hole, eh? they usually seem to snap off flush when i break 'em. J/k. thanks for clearing that up.