I made a drill guide for drilling out exhaust manifold studs. I had to drill out more than half on the drivers side so the guide proved extremely usefull. Thought this might help some of the doityourselfers.

It allowed me to drill lengthwise through the stainless studs perfectly centered with no problem. Cobalt bits of course.

To make one is easy. Strip of 3/8 thick flat mild steel about 5" long and 3/4" + wide. Each row of holes for the studs in the heads are 3.95" centered so I drilled 2 holes 3.95 apart in the steel strip. One hole was just large enough for a new stud to slip through. A new stud with a nut threaded down to the shoulder will attach the steel strip to the head.

On the other end 3.95 inches away I tapped a 8x1.25 hole and used the threaded drill guide from the www.boltmasterusa.com kit I ordered. The boltmaster setup cost $20 shipped for the single 8mm kit but the perfectly centered drill guide was worth it to me.

So attach the plate (using a stud and nut) to an open hole and then use it to drill a perfectly centered hole through the nextdoor stud. Of course this is for a stud broken off below the surface.

I found that as long as the broken stud was a little below the surface it was easy to wiggle the 3/8 plate as I hand screwed the threaded drill guide in so as to get it perfectly centered on top of the broken stud. Then snug up the nut to hold the guide in position.

I have a picture but am not allowed to post attachments.

Cheap and easy for the do it yourselfer.

Also my 3/8 porter cable right angle air drill with the big paddle switch was just to much of a PITA for the close quarters. I did a lot of research and found that the Hitachi D10YB close quarter drill was the most powerful at 4.6 amps and it was also the cheapest at $124 shipped (as compared to the 4 amp Makita which is around $200). I was going to post where I got it but it seems that it must have been a closout since it is no longer on their website. Sorry. Works great though.

The Milwaukee can be had at:
http://www.weldingmart.com/Qstore/p000482.htm
for $118 shipped so that would be my next choice. This is the newer version as well. It sells for $140 at Lowes.

 

Thanks for a great idea for a tough problem. Doesnt it make you feel great to put together a solution that works beautiful the first time? I printed that out so when its my turn for trouble I'll be ready.

 

Glad to hear it might help someone.

 

Mr. Obvious...

Worked like a charm! Not sure how I would of done it without your drill guide suggestion. Only thing I would add is to make sure the tapped hole of the guide is perfectly perpendicular to the flat surface of the guide (i.e. drill press would come in handy here).

Since mine was a little off, I was able to get a 3/16 hole drilled before it looked like I was going to hit the threads in the head. Luckily, I was able to get the rest of the stud out with an EZ-out! Just keep spraying PB blaster through the drilled stud for two days in hopes that it would soak into the threads.

Thanks again!

I was able to drill up to

 

Mr. O upload the pic to your gallery. You should then be able to post it in the thread.

 

When it was my turn for studs, I just welded nuts to the end of the broken studs. Had a few that took a few nuts, but all came out.

 

IAM INTERESTED IN OBTAINGING ONE FROM YOU IF YOU HAVE ONE FORSALE.

THANKYOU
DAVE LACLAIR
dlacl@yahoo.com

 

Really, I think you could sell a few of these guides, at least two!

 

I bought my guide, drill bits, drill bushing and strong easy out off ebay for around $50.

Worked beautifully on around 15 broken studs.

Recommend additional cobalt bits though. The bit it comes with won't last.

 

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