broken passenger side exhaust header stud
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5th Wheeling
Joined: Oct 2007
Posts: 46
Likes: 16
broken passenger side exhaust header stud
1952 F-1 239 v8
Looking for experience in removing a broken exhaust header stud.
1) Do I attempt to remove the whole header?
2) drill a pilot hole and try a remover?
3) weld a nut?
Asking for direct experience in doing this.
Parts Nerd Extraordinaire
Joined: Sep 2010
Posts: 4,367
Likes: 1,785
From: Western NY
My thoughts in no particular order:
*These headers pitted and worn like yours can be more prone than one would think to crack/crumble. I have my stash that I'm somehow saving to be brazed in 50 years when the supply of readily usable ones dries up.
*Used serviceable replacement headers can not uncommonly be had for bargains that outweigh the effort and risks of trying to save one. 7RT-9431 or 21A-9431 are commonly found on truck engines and 8AB-9431 on passenger engines.
*Heat (getting some glow) and a left handed drill bit would be my first attack.
*These headers pitted and worn like yours can be more prone than one would think to crack/crumble. I have my stash that I'm somehow saving to be brazed in 50 years when the supply of readily usable ones dries up.
*Used serviceable replacement headers can not uncommonly be had for bargains that outweigh the effort and risks of trying to save one. 7RT-9431 or 21A-9431 are commonly found on truck engines and 8AB-9431 on passenger engines.
*Heat (getting some glow) and a left handed drill bit would be my first attack.
Fleet Owner
Joined: Jul 2004
Posts: 27,294
Likes: 1,055
From: NM
I've had to remove that exact stud twice. What worked was placing a washer and nut on them, and MIG welding to the stud until the nut is completely full. Had to repeat a couple of times on one. Good luck!
I wouldn't try it with the manifold on the engine.
I wouldn't try it with the manifold on the engine.
Fleet Owner
Joined: Dec 2000
Posts: 25,378
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From: Central PA
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Laughing Gas
Joined: Sep 2022
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From: Pratt Ks
get new mounting bolts too, if you have to they make tube headers for these with the same dimensions as the manifolds so you shouldn't have to change your exhaust.
that manifold looks like the frame on my tacoma who knows if it will even survive the stud extraction.
Before you make a decision i would look into new tube manifolds/shorty headers.
that manifold looks like the frame on my tacoma who knows if it will even survive the stud extraction.
Before you make a decision i would look into new tube manifolds/shorty headers.
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Parts Nerd Extraordinaire
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From: Western NY
Thread Starter
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5th Wheeling
Joined: Oct 2007
Posts: 46
Likes: 16
I tried drill/extractor, MAPP gas, vice grips, flux core welding a nut. They won't budge. I just cannot get them hot enough to release from the header.
I contacted a local hotrod shop that rebuilt my 6-volt generator and will be bringing the headers to them on Mon Feb 19. They specialize in early Fords. They said they need a week turnaround to replace the studs and/or find me replacement headers.
This project started with just needing to replace my exhaust from the headers back, with a new complete kit from Dixie Exhaust Works: https://www.dixieexhaustworks.com/pr...exhaust-system
