Hello All am after some help and advice

So i had an exhaust stud snap when trying to refit the manifold and then the drill bit snapped off leaving me with this mess a 10+mm hole where the stud should go. now i don't have a tig welder so cant weld it up. is there anything i can do or is it scrap

thanks

 

Oh man, that is rough. Only thing you can do now is take the head off and have a machine shop bore the hole out. Good luck.

 

I'd try a "timecert" that inserts into a predrilled hole. I've used them several times on aluminum engines. No need to pull head, just buy appropriate kit, drill hole and insert timecert as directed. Even if you had to bump up to the next size stud, just file the hole in the manifold to allow for larger stud.

Brian.

 

I would think a remanned head may be more appetizing than trying to timesert it. I have used timeserts they are awesome, but $80 for a set anyway. How much is a remanned td6 Head?

 

I would go with the time sert. The cost and labor of yanking that head would not be appealing.

Let's be honest who thought, buy a tap kit and just go up a few sizes and drill the manifold to match lol

 

Did that on my Chevy. Went up from an 8mm to a 3/8” on the far rear manifold bolt that broke.

Of course, I ended up hitting a water jacket when I did that... A little thread sealant and it hardly drips though. Been that way 25k miles, and I haven't had to top it off in 10k or so.

 

Asking simply because I dont know.
I looked up time sert and it appears to be the same thing as a heli coil - would that be correct??

 

They are the same in only being a method of repairing threads. IMHO, Time Serts are by far the better long term option.
Time Serts are a "solid" sleeve and heli coil, well it's a coil/spring. Google it again and you will see the difference.

For this repair it's a Time Sert all the way.

 

The problem he is going to have is drilling out the broken off drill bit. Best done on a mill with a boring tool. You can try it in the truck, but the drill bit will walk sideways in to the aluminum and likely hit a water jacket.

 

a small tip acetylene cutting torch might do the job-get the broken bit and stud bright hot and hit the oxygen for a sec. seen this work well in similar situations...