Broken Ex Manifold Studs

[sdewitt at stx.rr.com]

Honestly, take the head off and pay a machine shop to do it. Unless the head is clamped in a fixture and the studs are drilled exactly at the stud center and sqaure with the head you will have problems down the road.
----- Original Message -----
From: DBF <dbf288 at eastlink.ca>
Date: Tuesday, December 28, 2004 11:41 am
Subject: Broken Ex Manifold Studs

> Good Day:
> 
> I'm doing a favor for a buddy of mine, that is replacing the ex 
> manifold gaskets on his '87 5k avant. As well, I would very much 
> like to keep the head on the car.  
> 
> I knew what I was getting myself into, as #1 cylinder was missing 
> both studs (broken) and #2 bottom was missing/broken as well. 
> After I got the manifold off today, I discovered #2 bottom had 
> something peculiar sticking out from the broken piece in the head. 
> I've seen it before, an easy out that was broken off! Man they are 
> hard. Good thing I can sharpen bits. 
> 
> Anyway, do any of you have pointers in removing the broken studs? 
> I've done it many times before on 'merican iron, and I suspect the 
> method is the same. I'm just a little leery about the aluminum 
> head. I have a good VSR DeWalt 6 amp corded drill, but what I lack 
> are right (or is it left, whatever the opposite twist bits are) 
> twist bits. I have used these many times before and you can get 
> lucky and remove the broken piece while drilling the hole for an 
> easy out. Any pointers/thoughts would be greatly appreciated. 
> Thanks all,
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