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Getting bad exhaust studs out?

Discussion in 'The Garage' started by gggGary, Jun 13, 2019 at 5:52 AM.

  1. gggGary

    gggGary Stop that! Top Contributor XS650.com Supporter

    Have an engine showing up at noon; broken, mangled exhaust studs, previous attempts made. What's worked for you? Gory details, :sick: methods,:guns: attempts, :umm: progress,:cheers: PICTURES to follow.
    The Meatball Garage, in action.
    MaxPete likes this.
  2. Ratranger

    Ratranger XS650 Addict

    Weld a nut on, might have to use a size up. Between having a solid way to turn it and the heat it tends to work.
    Signal, gggGary and MaxPete like this.
  3. Moabite

    Moabite XS650 Enthusiast Top Contributor

    Moab, utah
    No luck yet, project on hold as other more formidable problem with landlord wife going on.
    gggGary likes this.
  4. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Back in the ol' shop daze, all I could do was to drill them out. Progressing from small to larger bits, frequent resharpening from those doggone hard studs. Deep enuff to relieve the stud bottoming. Easy-out after each drill attempt. Sometimes successful, some had to go all the way to uncoiling the residual threads.

    Gonna try this?


    Edit: I still like this trick of yours.

    lakeview and gggGary like this.
  5. highboy_coupe

    highboy_coupe XS650 Addict

    I vote reverse drillbits. Winds them out as it weakens and agitates the stud
    Last edited: Jun 13, 2019 at 8:27 AM
    OHRider and gggGary like this.
  6. arcticXS

    arcticXS XS650 Junkie

    Lately, my favourite ez-out has become torx bits, drill a hole and hammer them in. Cheap and available,
    OHRider and gggGary like this.
  7. Moabite

    Moabite XS650 Enthusiast Top Contributor

    Moab, utah
    IMG_20190613_074024.jpg IMG_20190613_074042.jpg
    So welded nuts not work, rust too solid. Drilled one out, try easy out, drill little larger, try another easy out, drill larger till crown of threads, part of stud come out...probably have to drill out again and use next size larger (1/4-20) studs...but on hold for now unfortunately.
    gggGary likes this.
  8. gggGary

    gggGary Stop that! Top Contributor XS650.com Supporter

    I'd like to report this was a simple job and had amazing success.
    TwoManyXS1Bs, Moabite and Jim like this.
  9. mrtwowheel

    mrtwowheel Honda Etched On Brain Top Contributor

    What does that mean that you'd LIKE to report that it was a success? Does that mean that everything is now FUBAR?
    TwoManyXS1Bs, gggGary and Jim like this.
  10. Jim

    Jim The thrill of victory and da agony of da feet. Top Contributor XS650.com Supporter

    Welding a nut on has always been my go to.....

    TwoManyXS1Bs, Signal and gggGary like this.
  11. shotgunjoe

    shotgunjoe XS650 Hunter

    The welded nut trick usually works for me. When it doesn't I drill them out. One broken easy-out and you learn not to trust them, cause drilling hardened steel is the worst kind of headache
  12. gggGary

    gggGary Stop that! Top Contributor XS650.com Supporter

    You're on to me, can't sneak nothing past youse guys!
    Gory details with pics a bit later.
    TwoManyXS1Bs, Mailman and Jim like this.
  13. gggGary

    gggGary Stop that! Top Contributor XS650.com Supporter

    Mostly let pics do talking
    Welded nut on three times weld snapped off bolt first and second time, heated bolt red hot several times with acetylene torch. then bolt snapped behind the nut.

    nut. DSCN0152.JPG DSCN0153.JPG DSCN0154.JPG DSCN0156.JPG

    depth of the stud from face.


    Attached Files:

    Last edited: Jun 13, 2019 at 9:20 PM
    TwoManyXS1Bs, peanut and Jim like this.
  14. gggGary

    gggGary Stop that! Top Contributor XS650.com Supporter

    The rest of it.
    Drills walked a bit, hole is threaded and will hold the header.
    The hoyer patient lift works good.
    This set of LH drills excellent, walked right through that stud, jumping 2 or 3 sizes at a time. Biggest was 1/4" I went up to thread ID with RH drills.
    neither of the easy outs budged it. And I was on em hard as I dared.
    Sorry pics are kinda random order.
    Last edited: Jun 13, 2019 at 9:22 PM
    TwoManyXS1Bs, Mailman, peanut and 2 others like this.
  15. Signal

    Signal XS650 Junkie

    Welding a nut on is my first option, when they break off weld another one on.
    I have seen on youtube Alum will erode a stud but not aluminium. It takes time and some warmth but appears to work well. I have not needed to try it yet but intend to.
    Jim likes this.
  16. arcticXS

    arcticXS XS650 Junkie

    Those tapered, LH thread "easy-outs" are not very good
    imho. I have better experience with Ridgid/Ridge Tools screw extractor kits. Drill through the bolt, using the drill guide if possible, hammer the extractor pin in, slide on the drive nut, and use a ring wrench on it. s-l300.jpg
  17. peanut

    peanut XS650 Guru Top Contributor

    I only used an easy-out once and when it broke I vowed never to use one again.

    The whole premise is wrong . Screwing in an easy-out until it bites and then turning it ....just increases the pressure between the broken stud or bolt and the aluminium
    ...........the harder you turn the easy out the greater the expansion of the easy out taper in the broken stud or bolt ,
    Its analogous to trying to remove a stud from the jaws of a vice .......which squeezes harder on the stud ...the more you pull on the stud..

    if I cannot get the jaws of a pair of Stilsons on the stud then drilling is always the best option before further damage is caused to the head or stud and I always recommend using a proper drill stand for accuracy. How much is a replacement head going to cost !...;)
    TwoManyXS1Bs, Jim and gggGary like this.
  18. gggGary

    gggGary Stop that! Top Contributor XS650.com Supporter

    Yeah not my proudest moment...
    the hole is better straighter than the pic makes it look LOL.
    This was kind of a hack throw away third guy to try deal. Only did the one stud and that's prolly enough for me, :doh: Would tend towards; grind the bosses thinner on an exhaust collar, use nuts but no lock washers and leave the existing studs on the other side. But it's not my motor, guy had already bought, installed a replacement motor. :shrug:
    Jim and peanut like this.
  19. peanut

    peanut XS650 Guru Top Contributor

    I wasn't criticizing your efforts G :) i'm the first to resort to mechanical bodgery if I think i can get away with it

    Easy-outs are a major bugbear of mine :mad:
    lakeview, Jim and gggGary like this.

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