Turbo Manifold Stud Repair

[Aaronbrook37]

So now that my port and polish is almost finished on this spare turbo manifold for my B6T, it's time to get the studs repaired and sandblast her before it gets all wrapped up and insulated and popped on the car. As you can see, I'm going to need some help with stud repairs. Two of the studs have broken off and I was able to extract one successfully so far. That final top right hole is going to take some more drilling and then a careful re-tap for sure. I know the threads on that open hole are M8x1.25 because a tap spun in without too much effort. However, the M9x1.25 die spins freely on the two studs I have there. Anybody have any leads at NAPA or Fastenal or anywhere else on where I can grab some new studs? I may just replace all four to be honest, but to have two more would really help bolt on a turbo! Thanks all.

[M3NTAL]

What I did Aaron was find a stud that threaded into the manifold and bought 4 brand new studs then bought 4 nuts that fit the other side, really didnt matter what size they were going to be because they were all new.

Worst case just drill and tap it, or if you want to put your purse down you'll go with a t25 turbo

[Aaronbrook37]

What I did Aaron was find a stud that threaded into the manifold and bought 4 brand new studs then bought 4 nuts that fit the other side, really didnt matter what size they were going to be because they were all new.

Worst case just drill and tap it, or if you want to put your purse down you'll go with a t25 turbo

Good to know! That's a good point. I managed to get a little update because I was frustrated with that busted hole. My drill didn't have enough juice to drill enough of a hole to thread in some screw/bolt extractors on that evil fourth hole, so what I did was very carefully grinding through the middle with small carbide burrs and tapping and re-tapping the threads alternating my way down the old broken stud. I managed to get the little sliver that was left of it out as it broke down and heated up.



So then I did a final double-tap on both of the open holes and they're flawless M8x1.25 now. Nothing is more satisfying than a successful tapping!



I guess my only task now is to get those two other studs out before I go shop for four new ones. What do you guys recommend... a little heat, penetrating fluid, and a big pipe wrench?

[Aaronbrook37]

So looks like I might be heading to Fastenal on Monday morning to pick up some stud material. They carry threaded rod in M8 sizes and 1 meter in length. Cutting that up might just be my best bet unless I can find something at NAPA tomorrow morning.

[Aaronbrook37]

Success at NAPA. The guys at the desk weren't sure what to give me, so I had a look around the store and found this assembly. PN#605-1347 is a water pump stud kit that comes with Grade 8 studs, lock washers, and nuts. Presumably it's for some type of old V8 or domestic or something... who knows and who cares. They're M8x1.25 and a perfect fit into my open holes.




Now it's just a matter of getting a garage to remove those old studs and getting everything sandblasted before putting it all together! Unless there's a way I could remove the studs myself. I don't have acetylene torches or high heat equipment though unfortunately! Those old studs wouldn't come out with the double nut method and penetrating oil and a pipe wrench seems futile and barbaric. The threads seem oddball and damaged as my M9x1.25 die is a bit loose and the M8x1.25 die doesn't fit on it at all. Best get em out and have all four shiny and matching to hold onto the turbo better!

[fastivaca]

Re: Turbo Manifold Stud Repair

Crappy Tire has a stud removal tool. Just saw one there the other day.

Sent from somewhere west of here via Tapatalk!

[Aaronbrook37]

Third one came out... fourth one snapped. It's at the machine shop getting drilled out and re-tapped. My attempts to drill grade 8 exhaust bolts failed miserably.

[georgeb]

Shoulda welded a nut to it. If it breaks off flush, weld a washer then a nut to it.

[Aaronbrook37]

Shoulda welded a nut to it. If it breaks off flush, weld a washer then a nut to it.

I don't have that kind of equipment. I realize that would have been the easier way to do it now in hindsight, but that's no good to me now unfortunately having attempted to drill it. I didn't realize just how hardened these 25 year old grade 8 studs would really be! Here's hoping the carbide bits on the drill press at the machine shop are successful.