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exhaust screw-am i in trouble? (Read 300 times)

ralfyguy Serious Thumper Offline Posts: 932	Re: exhaust screw-am i in trouble? Reply #15 - 07/19/12 at 11:01:06 Did you buy one of those carbide drill bits? Carbide is harder than HSS and you should be able to drill a hole in the middle and try to mill it out from there. Or maybe give it another shot at extraction once you drilled that hole. It's gonna be tedious, but should be doable.
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RidgeRunner13 Serious Thumper Offline haulin' the groceries! Posts: 649 Mustang Island, Texas Gender:	Re: exhaust screw-am i in trouble? Reply #16 - 07/19/12 at 11:01:20 Take it to a machine shop or welder & have them weld a nut to the stud. I've done this many times with sucess. The heat from welding usually helps with getting the broken stud out, too.
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ralfyguy

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Re: exhaust screw-am i in trouble?
Reply #17 - 07/19/12 at 11:09:50

RidgeRunner13 wrote on 07/19/12 at 11:01:20:

Take it to a machine shop or welder & have them weld a nut to the stud. I've done this many times with sucess. The heat from welding usually helps with getting the broken stud out, too. Cool

That is a better idea even. Set the nut centered on the broken stud and get a tack weld right through the middle. If the weld is good enough, it should come right out.

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Re: exhaust screw-am i in trouble?
Reply #18 - 07/19/12 at 11:14:57

ralfyguy wrote on 07/19/12 at 11:09:50:

RidgeRunner13 wrote on 07/19/12 at 11:01:20:

Take it to a machine shop or welder & have them weld a nut to the stud. I've done this many times with sucess. The heat from welding usually helps with getting the broken stud out, too. Cool

That is a better idea even. Set the nut centered on the broken stud and get a tack weld right through the middle. If the weld is good enough, it should come right out.

Exactly right! And if it breaks off you can usualy just get another nut & try again. I've used this technique to get broken exhaust bolts out of heads. Sometimes it was easier to get a welder to it than a drill. Grin

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Re: exhaust screw-am i in trouble?
Reply #19 - 07/19/12 at 13:43:55

highlander10 wrote on 07/19/12 at 10:44:27:

a week or so later... the tap is still there and i spend 20euros in different dremel tools trying to dig around the tap so as to pull it out and then refill the hole with aluminium in liquid form. any other suggestions. I include a recent photo. Greetz savages

If the welding technique does not work, and you run out of options - then I still believe the dremel is your best bet. It is time consuming and will probably take and hour or two....along with a handful of grinding bits. I have used this method and it does work.

The common burrs won't work - you must get a diamond bit or the chainsaw ones. Not sure which color or size would work best - but below is a link to what the look like. I ground out a similar stud on a lawnmower block using this method.

http://www.amazon.com/Dremel-454-Grinding-Stone-16/dp/B000LNJX1I/ref=sr_1_11?...

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Re: exhaust screw-am i in trouble?
Reply #20 - 07/24/12 at 05:29:39

two weeks later! I did it. the tap and the screw are past!
Now the story goes like this. The outer half of the hole has diameter of 8mm and the rest half is as it used to.
I need new threads for sure but which solution is the strongest? first is as they told me Helicoil that i put together with lock tite after i tap with tap of 10mm and the other
one is that i fill the hole with liquid aluminium and hardener and then tap new threads over there.

Open again to all suggestions

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highlander10 YaBB Newbies Offline Keep Walking Posts: 32 Groningen, Netherlands Gender:	Re: exhaust screw-am i in trouble? Reply #21 - 07/24/12 at 05:31:57 and of course the picture
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Paraquat Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2206	Re: exhaust screw-am i in trouble? Reply #22 - 07/24/12 at 06:35:16 A helicoil could work but usually if it gets that bad I like to use a keensert/timesert. http://www.mcmaster.com/#key-locking-threaded-inserts/=ijmjo0 --Steve
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ralfyguy Serious Thumper Offline Posts: 932	Re: exhaust screw-am i in trouble? Reply #23 - 07/24/12 at 11:13:30 If the threads isn't stripped all the way out, tap it with a 5/16 standard which is about identical in diameter as an M8, but has a more coarse thread and you basically just cut a new thread over the old one. Then use a 5/16 x1 bolt.
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