Was replacing studs to upgrade them to the kit @Extinct sells and stud 6 of 6 of course snapped off. I tried to drill it out, was surprisingly accurate an bored straight through the middle, but still wouldn't budge. Drilled bigger and bigger holes until finally creeping up to the thread and despite heat, using picks, chisels, etc, that stud is just fused to the thread there. Wild because the other 5 studs came out without issue.

Anyway, I ordered a used one off eBay and in the process was surprised by how few LH manifolds are out there. New ones are NLA and used ones... I had the choice between like 4 and ended up choosing the best of bad options, but at least the one I got already had the studs removed.

So now with how rare these seem to be, should I throw this away or is there a way to resurrect and repair this? I guess somehow upsize the stud size? But that doesn't seem to leave much meat left on the flange.

 

Yeah, you did all the hard work. You can just helicoil it and it will be fine.

 

I've never done a helicoil before. I'll check out some tutorials. Can I make do it so that it will stay the same thread size/pitch as the two good holes?

 

Just put a nut and bolt on it?
Maybe even weld a nut on there...

 

Yeah, that is how the helicoil works. You drill and tap for a larger thread which matches the outer thread of the helicoil. When you are done the "inner" thread will be back to the original diameter and thread. Very common repair in machine shops. Considered equivalent in strength to the original in most applications. The Helicoil process is engineered to remove the minimum metal possible to retain the original strength.

 

Also, the helicopter is typically much stronger than original threads and stainless.

 

It should be here Monday. Will report back. Thanks all!

 

Helicoil and new studs installed! @Extinct do the studs get torqued to the same 30nm as the nuts?

Also zinc electroplated the rusty spacers and they turned out really great!

 

Yes, same torque. The great eight bolts can handle a bit more but we don’t wanna crack the manifold and given Land Rovers propensity for low quality metals. I am reluctant to increase the specification.