How are Yall drilling the studs out?

 

Like fish said, grind down busted stud level with the flange, then your drilling a hole through a shorter length of the broken stud, maybe a half inch tops. I center punch what I'm drilling since that makes it quick for the drill to find dead center. You use a drill bit just under the thread size of the stud to drill through the nub and then chase the threads with a tap to clean any remnants and face the flange threads to accept a new stud.

There are left hand twist drills for this too because many times just the friction and friction induced heat of the the spinning bit will begin to turn the broken bolt or stud your removing. If you can get enough exposed for long nose vise grips you can do that to turn it the rest of the way out.

If the drill doesn't turn the remnant or you can't drill dead center then you drill sized hole for a sized E-Z Out (I have five different sizes) which is hardened tool steel, left hand twist and use that to grab and turn the nub out.

With exhaust manifolds especially either super cool (Tom) or heat the flange to shrink the stud or swell the manifold just enough to turn the nub out with whichever method you'd like.

Sometimes just striking the flush ground stud with a center punch off center and at an angle can drive the nub around and out.

All are different methods to produce the same result.

 

I was thinking yall did the drilling with the y pipe still on truck.

 

? I had the Y pipe off. Usually the studs will shear off and be left in the manifold. The Y pipe doesn't have threaded holes so as long as you can get the nut off the Y pipe should drop. I drilled the sheared off stud with the manifold still on the truck. I really wanted to pull the manifold and drill it on a bench, but I was too afraid I'd shear off bolts going into the head.

 

I did mine right after a long drive. Nuts where nice and hot, came right off. Actually, the stud came off with 4 out of the 6. Lol.

 

....the easiest way to get er done, been there. Same for removing the exhaust manifold from the head, came out like buddah.

 

I changed mine over to bolts and lock washers. I used 30mm long, they stick out a few mm out of the threads. I could have used 25mm, but would have not used all the threads on the exhaust manifold. They bolts came from insanepowersports. I know, they are expensive...

 

The thought of bolts had certainly crossed my mind vs the silly studs. Just coat em with some anti seize and use a lock washer and it should be fine.