Re: broken exhaust manifold stud drill guide - Saab 9000 Bulletin Board - Saabnet.com
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Re: broken exhaust manifold stud drill guide
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Posted by BobS (more from BobS) on Sat, 3 Apr 2010 19:32:22 Share Post by Email
In Reply to: broken Exh bolts cyl#4 9000t, jack, Sat, 3 Apr 2010 12:45:36
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Made a drill guide that fit in the stud openings in the exhaust manifold and did a good job of holding the drill centered. Its .430 O.D. x .75 long with a .160 thru hole. One end has an .27 O.D. x .125 long extension that fits in the stud hole if the stud is broken off below the surface of the head.
Used a separate right angle drive versus one built into the drill motor, (its what I had). The left hand drill bits I had were to short (2 1/2" long) to reach the stud without the drill chuck contacting the manifold. I made a drill bit extension to reach, otherwise use a longer bit.
Used a .155 O. D. drill and #3 easy out with the point ground off (flat to the beginning of the spirals), so the drilled hole would not have to be quite so deep.
You can tell which studs are weak or cracked by tapping on them, a good one will ring and a cracked one will sound a bit less ringy or duller sounding. Listen carefully to several of them and you can tell the difference.


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