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Re: extractor Posted by skibumm100 [Email]  (#3255) [Profile/Gallery]
(more from skibumm100) on Sun, 24 Jul 2016 09:38:30
In Reply to: Re: extractor, skibumm100 [Profile/Gallery]
, Thu, 23 Jun 2016 06:05:03
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OK, time to update for posterity and to save someone from a BIG headache down the road. I'm still not done with this job as I've spent the last couple days trying to dig myself out of a big hole that I put myself in.
First off, here's a couple of pointers from the lesson I've learned so far:
1.) Don't think you can do this job with the manifold in place and get lucky by having the broken studs come out through the manifold. Just resign yourself to removing the exhaust manifold from the beginning.That means loosening a bunch of lines on the turbo and associated parts.
2.) Don't try to drill the broken stud with the manifold in place.
I tried to drill out the stud using the manifold as a guide. The manifold was shifted slightly and, even using centering punches, I got the punch mark off center on the stud. This led to drilling the stud of center. So far off center that there wasn't enough of the stud drilled to release it from the threads with a punch. Eventually i was able to break off a drill bit in the blind hole....fun. I had to drill another pilot hole next to the broke bit hole and use a carbide burr on a Dremel tool to cut away the material between the holes and the HS steel drill bit. I finally got the remnants of the broken bit and the two broken studs out of the head but I'm now left with two not-round holes in the head. Fortunately, the holes in the manifold are oversize for all but two of the holes and I should have some slop available. the current plan is to drill two larger holes, hopefully close enough to the original centers, so that I can tap them for a threaded insert like a Keen-sert or a Time-sert. I don't care for Heli-coils. This won't be a cheap fix.
If I would've removed the manifold first I could've started on-center on the stud and things would've gone much better. Using the centering punches with the manifold in place would've been OK but I should've waited until the manifold was off to start drilling.
The saga continues....
posted by 73.249.195...
_______________________________________ long-time listener, first-time caller Saab glutton for punishment
, Tue, 21 Jun 2016 05:58:11, Tue, 21 Jun 2016 20:39:36, Tue, 12 Jul 2016 19:52:06, Wed, 22 Jun 2016 05:09:15, Thu, 23 Jun 2016 06:05:03, Sun, 24 Jul 2016 09:38:30 <-- Viewing This Message
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