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 “Rigged” exhaust 
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Post “Rigged” exhaust
When i took my motor apart to repaint everything i couldnt get one of the hex bolts for the muffler out so i drilled off the head to get the muffler off then tried to use pb plast and vise grips to het the stud out (to no prevail) then i tried welding a nut to stud and using a ratchet to get it off but couldnt get a good enough weld on the nut it just kept snapping off, then i cut off the extruding stud and tried tapping it with a left handed drill bit and an extractor. The damn extractor broke off in the broke off stud so then i tried to drill into it again but i couldnt, then i tried to just bore out the entire thing with a larger bit but was just wreaking havoc on it so i stopped. Bolted the muffler back on and sealed the gap with some jb weld extreme heat..it pisses me off to do some janky shit like that after i just spent so much time and money getting it all nice but it works.


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Wed Feb 27, 2019 11:48 am
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Post Re: “Rigged” exhaust
your saying you broke an easy out inside the stuck stud?


Wed Feb 27, 2019 12:56 pm
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Post Re: “Rigged” exhaust
:lol: :lol:

And I doubt it will hold up to the heat.

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Wed Feb 27, 2019 2:10 pm
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Post Re: “Rigged” exhaust
So, my experience with the high temp jbweld for holding exhaust on. It does fine on the head itself unless it gets exhaust gas blowing directly on it. On the exhaust pipe, it'll be hit or miss depending on the heat transfer from the header pipe.

If it doesn't hold like you have it rigged, here's what to do to fix it. Cut the broken bolt shaft out from the top side of the ear on the head (the part it threads into). Have that ear built back up with aluminum welding (cost me 5 bucks at a local machine shop). File it completely flat where the gasket will go. Take a small drill bit and drill a hole for the larger bit to follow. Drill and tap with the correct size for the bolt you want to go back in there.

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Wed Feb 27, 2019 3:20 pm
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Post Re: “Rigged” exhaust


Wed Feb 27, 2019 4:34 pm
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Post Re: “Rigged” exhaust


Wed Feb 27, 2019 4:36 pm
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Post Re: “Rigged” exhaust


Wed Feb 27, 2019 4:41 pm
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Post Re: “Rigged” exhaust
The easy out is hardened. Put on a pair of monogoggles (cuz pieces will fly), take a center punch and hit the easy out. It will shatter off into small pieces. Take your time and you will be able to get that out at least. Then try again, but I would apply some heat to the head. Not a lot because you don't want it to warp, be heat will make the aluminum head expand faster than the stud. Then PB blaster, keep trying that.


Thu Feb 28, 2019 4:34 am
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Post Re: “Rigged” exhaust
when they are stuck. Just drill the bolt and heli coil it.

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Thu Feb 28, 2019 6:19 am
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Post Re: “Rigged” exhaust
The shop I previously managed would heat up the bolt and use wax to melt and penetrate down into the threads. Worked more times than any chemicals we tried.


Tue Mar 05, 2019 9:17 am
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