Broken exhaust manifold stud

BillysBug Learner Dubber

13 posts · joined Sep 2010 · 12 Jan 2011, 2:55 am

#821168

When stripping down the twin port engine for our beetle I managed to snap one of the studs off for the exhaust manifold (heat exchanger side of heads). Decided I could fix the problem with a stud remover kit, didnt read the instructions properly and managed to snap the bit in the bolt, then tried to drill it out and drilled off centre completely stuffing it now i have a hole in the wrong spot and have pretty much stuffed the head. Is it possible to buy another head and fit it or am i best to find a matching pair of heads?

Smiley Veteran Volks Folk

2,125 posts · joined Oct 2008 · 12 Jan 2011, 8:26 am

#821203

I can't comment of the machining or replacing of heads. But I have removed a broken exhaust stud in the past by welding a nut onto the remains. Because the heads are alloy the metal will not stick to it.
Get a nut that the hole is the same size or slightly bigger than the stud, place it over the studs remains. Then you weld down through the hole and onto the stud. Make sure you strike the arc onto the stud and not the nut so you get good penetration. Otherwise you'll just end up with a nut full of weld and no meat holding it to the stud, it'll just twist off.

I hope this helps or is at least something for you to try on the next one you have.

Smiley 😎

If you said I was a Volkswagen man, you'd be right.

waveman1500 Also rides a Honda

1,346 posts · joined Dec 2009 · 12 Jan 2011, 1:06 pm

#821242

In terms of a stock engine it really doesn't matter whether your heads match or not, so you can buy either just another one or a pair and put them on. Shouldn't be too expensive.

1972 VW S-Bug - For Sale!
1968-onwards Beetle panels and glass for sale

Thinker Seriously Crusin Dubber

162 posts · joined Oct 2008 · 12 Jan 2011, 1:09 pm

#821244

i am sure you could get the head fixed alot cheaper than replacing it.

1970 bug /1500 stock as a rock.
1976 standard bug ready to be modified 😁😁😁😁😁

BillysBug Learner Dubber

13 posts · joined Sep 2010 · 13 Jan 2011, 9:47 pm

#821451

Thanks for the info, unfortuately the stud broke off flush with the head so cant get anything on there which is a pain. Could the hole (that super mechanic me drill into the head off square) be tig welded up and then redrill and taped to suit? That the only way I can think of fixing it. Is there a difference between 1300 and 1600 heads if so is there an easy way to tell the difference?

Lucky Phil Wolfsburg Wizard

480 posts · joined Aug 2010 · 18 Jan 2011, 8:27 pm

#822118

There are two main reasons for a stud (or bolt) to break off.

The first (and least often seen) scenario is the stud failing in some way (sheared off or some other trauma).
If you use a stud remover kit, the drag on the thread is negligible and will come out easily. Often they can be removed with a small hammer and a sharp punch.
I have removed studs broken off in holes that were not blind and as the drill bit into the stud it wound it clean out the other side.

The most often seen scenario is when the threads are frozen together. There are many reasons for this (Rust, Galvanic corrosion etc.).
This is the bad boy folks.
The truth is that if you broke the stud off undoing it you will almost certainly break your stud remover trying to remove it!
Sure, Give it a go BUT stop before you break it. A professional will charge you less at this stage

greedy53 Bishop of Volkswagenism

3,062 posts · joined Mar 2006 · 19 Jan 2011, 6:51 am

#822166

can you get an drill onto it if you can drill a hole and use an easy out they screw in the oppirsite
way to a stud anit clock wise

👍👍😂🙅🥷😬🤓

barls Administrator Causer of Chaos and Mayhem

9,473 posts · joined Jun 2004 · 19 Jan 2011, 8:18 am

#822182

greedy53 wrote:can you get an drill onto it if you can drill a hole and use an easy out they screw in the oppirsite
way to a stud anit clock wise

he tried that greedy then broke the easy out

“We all pay for life with death, so everything in between should be free.” Bill Hicks
the chaos project - click me

Lucky Phil Wolfsburg Wizard

480 posts · joined Aug 2010 · 19 Jan 2011, 8:37 pm

#822247

The reason the drill went off centre is because the broken stud remover is harder than your drill bit and it is not going to touch it. The bit just slides to one side.
Once the stud remover is broken off in there I would recommend seeking professional help. There are many places that offer such services and many offer
a mobile service and will come to you.
Your head may be able to be saved. The broken stud remover needs to be ground out and a larger hole is drilled and tapped. A thread repair (helicoil) probably
won't work so a larger bolt can be screwed in, cut off flush, and a new hole drilled and tapped.
By the time you have paid for this you have probably spent enough to buy another secondhand head.