broken exhaust studs - GM Forum - Buick, Cadillac, Chev, Olds, GMC & Pontiac chat


1992-1999 Series I L27 (1992-1994 SE,SLE, SSE) & Series II L36 (1995-1999 SE, SSE, SLE) and common problems for the Series I and II L67 (all supercharged models 92-99) Including Olds 88's, Olds LSS's and Buick Lesabres Please use General Chat for non-mechanical issues, and Performance and Brainstorming for improvements.

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Old 03-10-2007, 11:55 PM   #1
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Default broken exhaust studs

Well I finally got done porting and polishing my manifolds. Then I realized that when I took them off my donor car I broke the studs off where the two manifolds connect together. Well I was trying to unthread them and it'* impossible. I got me a couple of titanium drill bits and broke them trying to drill them out. What'* the best way to remedy this issue? I was thinking about a tap and die set but if I can't remove the old studs what good will that do me.
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Old 03-11-2007, 12:08 PM   #2
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I don't know how much room you have left, but sometimes when you can't get them out the normal way, threading them in and out the other side works better.
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Old 03-11-2007, 12:44 PM   #3
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You talking about the two bolts for the crossover pipe? Try heating them up with a torch. They're baked in.

Can we get a pic of what you have to work with?
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Old 03-11-2007, 05:19 PM   #4
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Yes, i'm talking about the crossover pipe bolts. I don't have access to a torch. What about just cutting off the weld and getting some new brass exhaust bolts so I don't have to deal with it again. I have about 3/8 of an inch of threads to work with.
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Old 03-11-2007, 06:46 PM   #5
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Ok I got the bolts out. I have 2 final questions. Is it necessary to use exhaust manifold gaskets and what are there benefits to painting the manifolds as compared to just reinstalling them with no paint? Hopefully I will get them installed tomorrow.
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Old 03-11-2007, 07:37 PM   #6
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Paint will burn off and be gone in a week.

Use exhaust manifold gaskets and new donuts on the crossover and DP. Don't install anything without these 4 gaskets.
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Old 03-11-2007, 10:05 PM   #7
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Quote:
Originally Posted by egladman
and what are there benefits to painting the manifolds as compared to just reinstalling them with no paint?
No benefit at all, just keeps them looking pretty while they are on the engine stand. If you want a durable finish, look to ceramic coating them. It will insulate them as well. The quote from Jet Hot to do a front/rear/crossover set was $198

There is some grey epoxy based paint the resto folks use on iron manifolds to keep them looking like cast iron. It'* supposed to be pretty tough and bakes to a harder finish, but has no advantages other than looks.
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Old 03-11-2007, 10:16 PM   #8
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This is the only DIY coating I've ever heard of or tried that works:

http://www.bonnevilleclub.com/forum/...55&highlight=A
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Old 03-11-2007, 10:26 PM   #9
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Quote:
Originally Posted by willwren
This is the only DIY coating I've ever heard of or tried that works:
That sounds like the stuff I'm thinking of. It came in a can and you brush/roller painted it on REALLY CLEAN headers...as in scrubbed bright with a wire brush and dipped them in solvent to remove any grease or oil from the metal. Then brushed the stuff on, let it cure a little while, then lit up the motor to finish baking them. I don't recall it having any thermal qualities, just kept the grey cast iron manifolds looking like grey cast iron manifolds...as opposed to the dirty rust brown color of factory headers after the first couple of months of use.
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