Broken off exhaust studs

[kogafortwo]

I have two engines now where the exhaust bolt snapped off when I was removing the muffler. ONe is a 12 hp vertical shaft B&S, the other is a 10 hp Tecumseh HM100.

On the B&S, I tried penetrating oil and vice grips. All I did was mess up the short bit of stud still sticking out and made it worse. The Tecumseh has some clean stud still there and I don't want to touch it until I get some good adivce.

What's the best way to get these out? I can try to drill and use Easy-outs, but it's really hard to drill the hard bolt material without the bit wandering and damaging the aluminum block.

[Leaf Jockey]

The trick to drilling those out is to start with a small bit and get a nice centered hole in there. Good luck.

Scott

[nalabama]

And a Dremel tool should allow you a good shot at centering up and/or hogging out a nice starting point. Mapp gas heat and extended soaking in penetrating oil, coupled with judicious application of vice grips, have also worked for me in the past. Good luck.

[BigFish]

Grind the mangled up one flush and get ya a good center punch mark, and go slooow with a small bit, workin up to a larger bit, then easyout. LH drill bits make life easier...sometimes. Try hittin the other one squarely with a hammer, in a vain attempt to loosen, then throw some heat to it and vicegrip it out..... see I told ya it was easy!!!

[Phil G]

What's the best way to get these out?

A little lube, a little heat and a whole lotta prayer,
Good luck, Phil :)

[DiyDave]

Take a mig welder, weld a washer to the stud, then weld a nut to the washer. led it cool a little and take an impact wrench to it. Generally the heat from the welding heats the busted bolt or stud just enough to get it moving. I'd say this has worked 90 % of the time I use it!:cool2::cool2:

[pdoetsch55]

if you can heat the stud from behind or along side, try diesel or wd40 on the exposed thread portion. the heat will coax the diesel or wd up the threads into the rusty area. this may take several trys but will possibly safe you a block and some frustration. good luck

[kogafortwo]

Thanks y'all for the help. I will try the torch after I get back from:
a) fleeing hurricane Hanna (and Ike? and Josephine?) ...or...
b) 2 weeks of business travel
whichever comes first.

Gotta pack my bags and make sure my saws are all tuned up and chains sharp for dealing with the storm blowdown.

[kogafortwo]

I finally drilled it out and helicoiled it.

I will start a thread in a couple of weeks showing my complete rebuild of my chipper engine. It's coming along and my new rod, rings, and other bits are on their way from psep.