V1 Exhaust Manifold snapped off

[Metal Mech]

So while working on removing parts from the engine I found a snapped off stud on the exhaust manifold.
I didn’t snap it, found it that way and it’s been that way based on the rust.
So how screwed am I?
I got the rest of the exhaust nuts removed no problem, so just this one to get our.
I already planned to replace the studs.
I was always worried about this from the start. Snapped bolts that need to be drilled are my worst nightmare.

 

[Desert Sasqwatch]

Center-punch, drill and an easy-out are your best bet. The broken off stub is too deep into the hole to try to tack weld a bolt end onto it. Not fun, so sorry. Good luck.

 

[Rttoys]

Weld a nut to it and remove the stud with a wrench. I Do it all the time on LS heads. Steel doesn’t weld to aluminum, so you won’t hurt the head.

 

[G Atsma]

Weld a nut to it and remove the stud with a wrench. I Do it all the time on LS heads. Steel doesn’t weld to aluminum, so you won’t hurt the head.

Look at the pic. It broke deep in the hole. Nut???

 

[Vwsaabvt]

Look at the pic. It broke deep in the hole. Nut???

yes. put the nut at the surface and weld it, your weld material will fill the void below the surface and then fill the nut. The weld will only stick to the nut and the broken off piece of stud not the aluminum head, and the heat from welding will help remove it. You may have to attempt it multiple times but it works great.

 

[comegetjoe]

Told you we can drill it out.
Welding it looks fun, too, but I dont own one of those.

 

[Rttoys]

fast forward to the 6 minute mark

 

[Joebob]

I had the exact same problem in the exact same place. I practice welding a bolt inserted into the donor aluminum motor mounts, I blistered and messed up the aluminum. At least for me with a flux core welder, I was not comfortable welding on the head. I did end up using a set of left hand drill bits from harbor freight and a set of EZ outs and got the stud end out that way without damage to the head.

Take your time and I found the stud material is not that hard but make sure you don't drill too deep.

Joe

 

[Gtstorey]

If the bolt is stuck, left handed drill bits aren't really required. If it is able to turn it in more, that just means it broke loose. The only time I would worry about it is when the hole might be deep enough that if it screws in farther, you can't reach the bolt. If that starts happing, stop drilling.