Broken Ex Manifold Studs

Bob Rossato bob.rossato at
Tue Dec 28 19:44:29 EST 2004

I believe Scott Justusson (sp?) posted this trick a long while ago.  If
you, or someone you know, has access to a MIG welder use it to build up
the end of the broken stud a little bit at the time so that it protrudes
beyond the surface of the head.  At this point you could also just tack
on a nut to wrench with.  The heat from the welding has the benefit of
tending to break free the stud.


> -----Original Message-----
> From: quattro-bounces at 
> [mailto:quattro-bounces at] On Behalf Of DBF
> Sent: Tuesday, December 28, 2004 4:41 PM
> To: quattro at
> 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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