Exhaust studs - How to remove?

Grind or file it smooth, drill out a small hole in the center of the stud, then use a screw extractor bit if you can. If you can't, drill out the entire stud, then drill an oversize hole and install a thread insert. Follow the instructions on the drill bit sizes to use and where to use thread locking compound. You can do it with the head in the car.

At least that was what I did once in the past. Techniques may have improved in the 20 years since then. :)

Slip a nut over the end of the stud and weld the nut to the stud. It doesn't matter that if there is a 5mm or so gap, a wire-feed welder will fill that right up. After it cools, it'll come right out but you will probably need to helicoil the hole.

Some folks like brass nuts on exhaust studs to prevent this problem. However I like to use stainless steel nuts on exhaust studs. I still use anti-seize compound with them and I've never had a set stick.

Tony

A problem we've all had from time to time Karls.

Good luck

Remove "YOURPANTIES" to reply

MUADIB®

The Peacemaking Meeting scheduled for today has been cancelled due to a conflict.

Good God aren't you in a mood tonight LOL LOL LOL LOL !!!!

Susan S.

It's fairly easy: Weld an 8mm nut (13mm head) on the remaining stub, get it red hot and allow it to cool a little. Then turn the stud out with a normal wrench or whatever tool you like. The heat generated in the process should help loosen the stud too. If the nut snaps off, try again. You can try it dozens of times. Just be careful not to weld the aluminum around the stud. Weld won't stick to it, but it will melt it.

Jan

I split all my nuts (shot in front of open goal there :) because the first couple were a bear to loosen and didn't want to take the risk of what you had happen. As a replacement I intend to use brass - the dissimilar metal in contact with eachother may not be a good thing, but they'll split a whole lot easier.

My friend's used a similar trick -- he drilled a small hole (small enough not to compromise the stud, large enough not to break) in the middle of the stud, and then JB-welded in an allen key. Turned right off. Then again, it was not an exhaust stud and was on a BMW...

-Kevin

Helps to have a good sense of humor.............or at least a sense of humor.

I keep a spare one in my pocket, right next to my stubborn nuts.........

Remove "YOURPANTIES" to reply

MUADIB®

The Peacemaking Meeting scheduled for today has been cancelled due to a conflict.

And we all know brass nuts don;t rust like steel ones do.

That open goal was nice............But splitting nuts.............I don't know about that............Splitting hairs.........now that's different.

OUCH!

Remove "YOURPANTIES" to reply

MUADIB®

The Peacemaking Meeting scheduled for today has been cancelled due to a conflict.