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Subject:Re: Broken exhaust stud.... bummed... need ideas
Date:Sun, 2 Aug 1998 09:40:27 EDT

In a message dated 98-08-01 10:40:35 EDT, Paulc@SNET.NET writes:

> Has any broken a stud while removing the exhaust system on a 1986
>  Watercooled?

Yes.  I had two broken bolts in a used engine I purchased.  Luckily I noticed
this before I installed the engine.  I spent nearly two weeks trying Liquid
Wrench, drills, taps, and various forms of "easy-outs".  None of which were
easy!  None of which got the stud out!

>  Is there a way to extract this in the vehicle?

Finally, I took the whole engine to a machine shop here in southern California
that specializes in removing broken studs/taps/bits/outs, etc.  Luckily, they
were able to place thewhole engine in their jig.  They did a really
professional job removing the whole mess with a LASER and then installing a
stainless steel threaded "insert".
I surely hope you fair better than I, but I would thinktwice before investing
too much time before talking to a professional at this.

Good luck,
Jim Davis