broken exhaust studs B cat

I hold a nut up to the broken stud and then weld the stud to the nut, I use a nickle rod that I call a missle rod, then just wrench it out.

 

i second puncher's way---its the only way that will really work

 

i use a drill and easy out

 

patience!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! and lots of beer.

 

a drill and easy out---wow---not fun --that bolt will be harder than priests dick during lent--and the last thing you want to do is break an easy out in there cause it will be harder
but what ever works for you --i personally love the fill the nut with weld--let cool and then un thread it

 

heat the remainder of the stud and melt some candle wax onto the broken stud... it's a great lube and sometimes allow the stud to come out very easy...

 

I start by tacking a flat washer to the stud,then the nut. I have also had luck on a few by taking a small punch and tapping it counter clockwise and it screw out. Also when u put ur new ones in,put some anti seize on the threads.makes it easier to replace next time.

 

CAT has a kit that aligns with the other good removed exhaust bolt holes and uses the step up drill bit process. Because the stud was heat tempered you may as well forget doing anything but drilling it out. The kit ensures you get a pilot hole centered on the bolt. Once you get the bolt drilled out you need to elongate the holes in the manifold so that when it moves it won't break the stud off again. CAT had a message out there about how much to elongate. I believe it was equivelant to a 5/8 inch hole.

 

If you have the part off of the machine, you can go to a machine shop and have them use a EDM (electron displacement machining) to remove the stud or what ever. Great for broken tooling in soft aluminum.