Broken Ex Manifold Studs

Nadjkovic Kraig A TSgt 552 CMS/MXMVC Kraig.Nadjkovic at
Tue Dec 28 18:49:49 EST 2004

 You can get left hand drill bits at Auto Zone, but unless I owed this guy a
HUGE favor, I'd have him have someone else do it.  If you want to help him,
take the head off and point him in the direction of your favorite machine

-----Original Message-----
From: quattro-bounces at [mailto:quattro-bounces at] On
Behalf Of sdewitt at
Sent: Tuesday, December 28, 2004 5:31 PM
Cc: quattro at
Subject: Re: Broken Ex Manifold Studs

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>
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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