#3 exhaust stud drill and tap

[Jimbug57]

The nut came off the lower stud on #3 exhaust. It stripped when I tried to put a new one on. There's not enough left of the stud to "double nut" it out. I can't budge it with vice grips.

I have the drill and tap for a step stud, which I also have. I've done this job a couple times - about 20 or 30 years ago. I'll try to cut the old stud off flush with the head, then drill a pilot hole and work it up to my 8.5mm drill bit, and tap with 10mm x 1.5.

I don't know how flush to the head I can cut - don't want to damage the sealing surface. I don't have a grinder. Also worried about getting the hole centered. I don't have a center punch.

I kinda think I know what I'm doing It has to be done today though. Please send any advice my way and wish me luck - Jim
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Repeat after me "I am smarter than metal!"

[fez68]

just cut it off then make it nice and flush to the head. like you said use a small "new" drill bit in the center of the old stud, if it goes off center just angle the drill to get it back correct. then you can drill it out with the proper size for the 8mm 1.25 stud. then tap it . Ive done this numerous times. i would avoid the oversized stud if you dont need to. then install a new 8mm stud. I make my own from stainless steel bolts and cut off the head. or buy some.

[fez68]

cut it off and use a sharp file to get it flush with the head. you could also try and run a die over it before and see if the nut goes on. I just did that also the othe day. the studs looked shitty but after i ran the die over it the nut went on nicely. try that first and then go about with the cutting.

[fez68]

can you post a pic of the stud ?

[empi3]

Check this out

"Cylinder Head Exhaust Stud Drill Jig"

https://www.thesamba.com/vw/forum/viewtopic.php?p=8801600&highlight=#8801600

Hope this helps and good luck!!

Steven
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1970 Beetle
1956 Ragtop Beetle

[anthax]

Weld on a nut on what's left of the stud and slowly work it loose.
It might need several attempts, but work very well.
I use this method almost weekly at work to remove snaped off and striped bolts.
No use in drilling and ruining the stud, when it's easier to just weld and remove.

[VW_Jimbo]

[Jimbug57]

Cut the stud off as close as I could get it, then filed it flush.

This is the second of 4 pilot holes. The final size was 8.5 mm. It was slightly off-center but it didn't seem to matter.

Ran a 10 x 1.5 tap in until I could feel it through the back wih the tip of my finger.

I double nutted the step stud in until it tightened up firmly and it was in up to the collar of the stud.

Thanks for all the responses guys, really appreciate it - Jim
_________________
Repeat after me "I am smarter than metal!"

[67rustavenger]

Whad a bitch of a spot to drill and tap an exhaust stud!

Nice job!
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GFY's Xevin and VW_Jimbo!

[Cusser]

Good job; I have done similar a long time ago, drilled and tapped to 8mm x 1.25mm. I figured the piece of old/broken stud in there would hold it, and it did.
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1970 VW (owned since 1972) and 1971 VW Convertible (owned since 1976), second owner of each. The '71 now has the 1835 engine, swapped from the '70. Second owner of each. 1988 Mazda B2200 truck, 1998 Frontier, 2014 Yukon, 2004 Frontier King Cab. All manual transmission except for the Yukon. http://www.thesamba.com/vw/forum/album_page.php?pic_id=335294 http://www.thesamba.com/vw/forum/album_page.php?pic_id=335297

[fez68]

I am glad it all worked out

[MrGoodtunes]

Best of all is that you did it using only basic hand tools!