twisted exhaust manifold studs

[Boggin]

While taking the motor out of my 79, the exhaust manifold studs that hold the y-pipe on twisted right off. i was thinking, hey great chance to put on some headers. but the cheapest ones out there are the summit ones ($119) and they told me its $97 to ship them, so im still looking at over $200 which i didnt really wanna spend on something over a couple of twisted studs. rather buy some body panels or soemthing first, then get headers after all the neccessities are taken care of.
so i have no idea what to do with them, is there any way the cast can be welded? i got a mig and stick so ill weld bolts on where the studs are supposed to go, IF it can be welded. , otherwise im thinking just drill/ tap so much into the manifold and put a new stud in there. if so, how much should i tap into the manifold? can i get an inch of treads in there or so?
thanks a lot!

 

[snoopdoggie]

Drill and Tap is the way to go. You don't say what motor/manifold you have but if you can get at least 3/4 " of thread it will be fine. If the holes go through the manifold you can drill the studs out re-tap or heli coil them. It can be done with blind holes too but just a little more difficult. Location is not real critical. A 1/16" off from original location should not hurt. There usually is some play in the Y-pipe flanges.

 

[nitrofan1]

+1 on the tape-n-drill. What engine is in it? 2wd or 4x4? Auto or manual?

 

[Boggin]

thanks guys, its 351m, auto, 4x4

a member on another forum told me about these 'clamp-a-stud'. designed specificly for broken exhaust manifold studs

 

[Sasquatch_Ryda]

Bust em off and drill out the part left in the manifold and then use a bolt that is long enough to go through both flanges with washers and lock nuts. Makes it super easy if you ever have to remove it again, because if it breaks again the bolt just falls out and you install a new one.

 

[Boggin]

thought about that but if i remember correctly it isnt that simple, the shape of it is slanted so i dont think it would work.

 

[shane96ranger]

Another thing I've seen done is to drill it out and put a wheel stud in it. Do you have enough room to do that?

EDIT: Is that pic the vehicle you are working on? It looks like you could drill straight through it, and then pull the wheel stud through the top.

 

[Boggin]

nope thats an example of the 'clamp a stud'

 

[shane96ranger]

nope thats an example of the 'clamp a stud'

Oh damn, sorry. Do you have pics of your situation?

I feel for you bro, I spent the whole day working on exhaust yesterday.

 

[Boggin]

ill pull the manifolds off today and try to put up some pics this evening

 

[Boggin]

damnit, forgot the camera

but i did pull the exhaust manifolds and carb and brought it all in the garage. the drivers side manifold already had a hole throught it, looks like it was burned through with an acetylene. so the other side had a nut on it and i went to canadian tire and bought a new propane torch and heated the shit out of that side and unscrewed it and it came out fine. the other 2 on the other manifold not so much. 1 side is gonna have to be drilled and tapped and another stud put in there, the other one i can drill through and stick a bolt through the other end.
man its gonna be a bitch drilling through them i can see it coming

 

[Boggin]

oh and reason i pulled the carb, im gonna rebuild it later tonight. but thats besides the point

 

[shane96ranger]

Can you use an easy out with it?

 

[Boggin]

i bought a stud extractor, same type of deal as easy out, and its not working worth a damn

 

[shane96ranger]

i bought a stud extractor, same type of deal as easy out, and its not working worth a damn

Have you tried heat?