Vince,

The simple fix would be to drill out the hole, retap to 10mm and use a
step-down stud, 10mm to 8mm.

A better fix would be to use an insert and keep the 8mm stud size.

Cheers,

Jeff

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@GERRY.VANAGON.COM]On Behalf
Of Vince Jahn
Sent: Saturday, November 27, 2004 11:27 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Broken exhaust studs

Hi all, !

I was just applying my last nut to install one of the exhaust manifolds on
my recently reconditioned heads, when you guessed it, the stud gave way and
it popped right on out in my hand. I tried replacing the stud with a metric
number 8 bolt with a 1.25 pitch to see if it would grab, but no such luck.

I guess I should be grateful its not stuck in there, but was wondering what
the pro's usually do in the tricks of the trade.

1. I could chase it again with a new tap, and hopefully scare up some new
threads in the process. or
2. Someone said to fill the hold with epoxy and then tap it again.  I'm not
sure if these approaches will even work.  Should I just go to the next
largest size (what ever that is) and try re-taping it again. ?  Does someone
make a gizmo (like a heli coil stud that will self tap?)

Don't even want to pull the head as I am just about finished with
everything.

Any advise would be appreciated. Thanks.
Vince