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Re: drilling into an alum head? Posted by TML [Email] (#2212) [Profile/Gallery] (more from TML) on Tue, 10 Apr 2012 08:51:20 In Reply to: Re: drilling into an alum head?, DanaH, Tue, 10 Apr 2012 08:37:43 Members do not see ads below this line. - Help Keep This Site Online - Signup |
Replace them one at a time, starting with the short ones. That way, if one breaks off, at least you have some holding it in place. That will give you time to decide how to proceed, and still be able to drive the car. Drilling into a broken off stud while the head is in the car is difficult at best because of the limited space and the angle of attack, and can be downright nasty depending on which one it is (I'm thinking about the ones that are directly behind the water pump and a/c compressor). I did exactly what you're worried about, drilled too far and through the head, which eventually led to having to replace the head. I temporarily fixed it with a tapered stainless plug, but the different contraction and expansion rates cracked the head. Even on the studs that didn't break off, I had minimal success getting them out with the double nut technique; no matter how tight I did those nuts, it was still the nuts that turned, rather than the stud. Once I had the head on the bench, extracting the studs was much easier, using a vice grip flush to the head.
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