Broken Stud Removal in Exhaust Manifold

We have an exhaust manifold from a 64 Oldsmobile that has two broken and seized up studs that need to be removed, and also one hole that needs brazed up.

[johnsmith]

ABom, You are a young man and I am 73 YO in a month. I have seen 10, 000 broken studs and broken bolts removed in my life. I am not a machinist. And never will be. But, what I saw you do in this video was the most accurate and professional way to remove a broken stud that I have ever seen in my entire life. Sir, it is a joy to watch you work. I salute you for your astounding knowledge. I think you are genius. I know you would never admit to that, but you are. If I owned a company you could name your own salary to work for me. It is a pleasure to see your videos. I am sure your Dad and Granddad are incredibly proud of you.(I saw them pictured in a previous video. I and think they are Dad and Granddad. If not please forgive me.) Oh, what you called a butterfly are what we once referred to as a heat riser. Of course, they are no longer on automobiles. Anyway, That is not being critical, just you are young and may not have known. Of course, vernacular has changed a bit in the last 70+ years. I cant wait to see more of your videos. You are never too old to learn and I always learn from you. If I had had a son, I would want him to be like you. My sincere thank you for these informative videos.Keep up the good work. John

[dashlamb]

Adam, you made it look easy! I've done similar "broken exhaust stud" removals with a cordless drill, countless broken drill bits, Benzomatic Map/Pro torch, never quite finding center - center punching, and enough cussing to make a Cape Cod sailor blush. As a mere mortal, I've always wondered how a Machinist God would remove a broken exhaust stud. Now I know. Backyard mechanic Troglodytes, like myself, can only give thee Worship. Thanks for sharing.

[jamesharold]

Great job I learn something every time I watch you. I am retired now but you make us older guys smile for doing the job with care and thinking about what you are doing. Hats off to your Dad and Grandfather for teaching you the correct way. Keep going young man thanks.

[williamlane]

This obviously isn't about saving time. It's about doing it correctly by a skilled Craftsman. Nice work.

[cozmium]

I have several classic cars and the amount of rusted out bolts i've manually drilled out and/or had to re-tap is enough to make you need a beer. Watching this was extremely satisfying. Thanks as always Adam, love to see you work - even on the most simple of projects it's extremely cathartic.

[thegoodearth]

The beauty of watching your work, Adam, is that you never deviate from aiming for precision at each and every step. This is precisely why your skill set can be so readily deployed across multiple disciplines; everything you approach is approached first with a plan, then with precision setup, followed by a series of possible solutions, starting first with that which is least invasive. Even the setup and order of your shop reflects precisely this same approach.

This is why I learn so much from your videos. I am not simply seeing ways and methods for accomplishing a variety of jobs, but rather the mindset, attitude, and thought process that stands behind the methods.

DCox

[brianwood]

Man, I can't believe all the negative comments. This craftsman was illustrating the many different and separate skills it takes to do a very precise job, the the best way he knows how. I would do it his way if I had the equipment.
Your customers will be happy with the results.
Ps, there should DEFINITELY be a metal (copper sandwich) gasket between the manifold and head. Then re-torque the manifold bolts in a couple of hundred miles.
Nice work & well explained.

[tm]

Real man doing real work. GOD bless you brother from a 22 yr Volvo expert certified technician. I have seen my share of rusted exhaust bolts and what not. We are a dying breed. Hard to find anyone these days under 40 years old that can fix anything other than a computer. Subscribed

[silleywilley]

As a 20 year mechanic, I can appreciate the precision here Adam. Usually I’m doing this overhead getting hot chips down my neck and penetrating oil dripping in my eyes lol. Then it’s still crooked and I end up pulling some threads😂 nice work as usual my friend.

[sharkrivermachine]

Boy does that bring back memories. When I had my automotive machine shop that was a daily job. Mechanics would bring all of their broken bolts to me. The bigger problem was when they tried to repair it themselves and broke a tap, drill, or ez out in it. Thanks for sharing.

[rogerbois]

I'm a tool maker and what I have done in the past with broken bolts was weld a bead inside of the washer hole smaller then the bold dia. Then weld a nut on top of the washer. After it cools the heat and shrinking will loosen the bolt. Then on screw the broken bolt out. Other times I drill a hole through the center of the broken bolt just under the tread depth and with a center punch collapse the tread wall out. Both work well.

[AmosBHaven]

What REALLY surprised me was how the owner of the car got all those manifold bolts out, and ended up having to bring the manifold with head attached! Thumbs up to BOTH of y'all!

[ronrobertson]

Refreshing to see a PRO at work using patience and experience to do the job.

[jm]

I worked in the exhaust business for many years, and one of our specialties was removing broken studs from exhaust manifold, and the one in your video was one we would see a lot, and sometimes we did not have the luxury of doing it on the bench, we would almost always have to service them on the car, Chevy's where the worse, with there 3/8s stud, ford's where commonly 7/16 of which made it a little more easy as well where Chrysler, I have literally removed Chevy studs that look like an hour glass and was even told you will never get those out they will snap specially when you start putting heat around them, well to me that was a challenge and my boss after they where cooled would put them on display in the waiting room for all to see, and some even had some twist in them, the one in your video I would have used a small brazing tip on my torch heated up the ears of the manifold and since there was some stud left on the other side of the ear, taken plyers and reversed the stud just enough to poke through on the exhaust end to braze or MiG on a bolt enough on the old stud that is now protruding enough to catch some meat on it, heat up the ear and with a ratchet slowly back it out, I very rarely had to drill out.I have literally done 100s of these, not to offend, but in the time it took you to set up the manifold in your drilling jig I would have already had both studs removed with no damage at all to the manifold, and all what would have been left was to chase a tap through the holes and good to go, like I said we did these well still on the car, and as for the heat risers like tat set have seen a lot those froze up and removed a lot of them basically the same way you did,

[ianstoysmgs]

Same old story, having the right tools for the job and patience. 10/10

[nakamakai]

Adam, this is not a trivial problem, and thank you for sharing a correct way to do this for those who know-how and have and the correct tools. Not all of us have such a complete shop, nor the experience and skill-memory to do this on the spot, but that's what these videos are for. Well done, another great bit of content. Thanks.

[ttokar]

Всю жизнь проработал токарем в России и в первый раз вижу что бы так аккуратно высверливались старые шпильки и остатки резьбы удалялась как проволока. Это просто СУПЕР !!!
All my life I worked as a turner in Russia and for the first time I see old studs drilled so neatly and the remnants of the thread were removed like wire. It is great !!!

[making]

Watching those threads peel out in a nice spiral was extremely satisfying

[stephenshoemate]

A friend showed me the best way in cast iron. Heat with torch until red hot, and tap a couple times with a hammer. Drop a washer over it, that slightly clears, and arc-weld the washer to the stud through the hole. Put a nut on top, and weld it to the washer. Let cool for 5 or so minutes, then screw it out. Best method I've ever seen.

[ricktalbott]

I've seen guys drill a small hole in a broken stud and like this where a little was sticking out, put a nut around the stud and with a wire feed welder weld the nut to the stud. Let it cool and since the center was drilled the stud can shrink and then come out pretty well that way too. I'm not going to judge how you do it because every chef has their own way to cook !