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removing exhaust manifold studs
Posted by: gmgmtl ()
Date: September 11, 2007 12:43PM

Is there any trick that helps remove the exhaust studs? I'm soaking them in PB now, would heating the manifold around the studs help? Has anyone found that welding extra material to the stud helps to keep it from breaking where it has corroded?

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Re: removing exhaust manifold studs
Posted by: MattNall ()
Date: September 11, 2007 12:55PM

Heating is the best...

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Re: removing exhaust manifold studs
Posted by: marv ()
Date: September 11, 2007 01:10PM

Applied heat to one of mine and it still would not break loose. tried to drill it out but now the cast iron was so tough a bit would not penetrate. Took it to the local machinist and he could not drill it either. he cut the ear off and welded a new piece of cast iron to it and then drilled and tapped the new piece Walla.... somehow the heat made it hard hard hard. I know heat works but be careful how much. replaced with stainless steel studsand a little neversieze Hope you have better luck



Edited 1 time(s). Last edit at 09/11/2007 01:12PM by marv.

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Re: removing exhaust manifold studs
Posted by: RthrDent ()
Date: September 11, 2007 01:12PM

I just did this a few weeks ago. PB din work. Heating with a torch din work. Heating the whole manifold in 400 degree oven DID work. Don't ask me why. Well, three of em came out that way. One was still too tight for my jam-nut method and I had to drill it out. If you're really really good and pick the right drill size, you can drill out the stud and not damage the threads. Forget stud extractors, even the best quality I could find wouldn't budge the rusty studs. Keep in mind that this was a lifetime California vehicle so it wasn't too bad. Your results may vary.

Allen and Stacy, Golden Valley,AZ
Facebook: [www.facebook.com]
[www.facebook.com]

'61 Lakewood
'65 Corsa turbo convertible (former)
'64 Spyder convertible (former)






"I love the smell of oil smoke in the morning."

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Re: removing exhaust manifold studs
Posted by: gmgmtl ()
Date: September 11, 2007 03:01PM

Thanks for the tips. My first set I got 3 out of 4,with the 4th I discovered that easy outs aren't. This second set has better studs so I might have better luck. A neighbor suggest using a air hammer to vibrate the area. Not as a hammer, but just lay the tool across the the manifold above the stud and let it vibrate, spraying with PB every now and then. I will definitely replace with stainless.

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Re: removing exhaust manifold studs
Posted by: TheL36Driver ()
Date: September 11, 2007 06:36PM

Chuck up in a big vise, heat manifold ear dull to medium red and remove stud with vice grips. Do NOT heat to white hot as it burns up the cast iron (ask me how I know).

I've owned three too many Corvairs.

Carl in St. Joseph, Mo.
'62 Monza coupe W/110 hp. Replaced the turd 140.
My other car is a '67 Corvette.
[forums.corvetteforum.com]

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Re: removing exhaust manifold studs
Posted by: beguiled ()
Date: September 11, 2007 07:24PM

I had to drill mine out too, rather than retap for new studs, I just used stainless bolts and nuts from manifold to pipe, no problems yet anyway.

Shawn S.
Charles City, Iowa
1962 Corvair Monza (Black with Red interior)
1963 Corvair Spyder (Red with Black interior)
Member of ICE (Iowa Corvair Enthusiasts)
<a href="[s14.photobucket.com]; target="_blank"><img src="[i14.photobucket.com]; border="0" alt="63 Spyder_small"></a>

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Re: removing exhaust manifold studs
Posted by: Mike J ()
Date: September 11, 2007 08:42PM

I took mine to a machinist. We heated the studs up to "RED HOT" and tried to twist them out. No go. So we broke them off, drilled a little "pilot" hole in them and then he took his torch and "blew them out" a little at a time. NO damage to the threads. We cleaned them up and I installed new ones.

It cost me $20 a log. Of course, I did one at a time. Fixed one, installed my new dual exhaust and then when tightening the second one, stripped them .... took 3 days total. $40 for all plus another like $6 for the studs.

Mike J
Northern Calif
Rescue, CA

65 Corsa ~ Sold !!
www.fquick.com/MikesGarage

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Re: removing exhaust manifold studs
Posted by: playerpage ()
Date: October 04, 2019 10:19AM

Me being me, does anyone have a picture of what we're talking about?

____________________________________________

Eric C. Player, Porterville, CA
Member: CORSA National, Central Coast CORSA, South Coast CORSA, and San Joaquin Valley Corvair Club
THEN: 1965 Monza 110 Canary Yellow
1967 Monza 140 Red
1966 500 110, Black; nicknamed "Shadow"
1965 Monza 110, Camaro Yellow; nicknamed "Silver"
NOW: 1966 Corsa 180 Turbo; nicknamed "Bluvair"

"It would not have helped if I had [taken notes], as he would start a paragraph with, 'It is therefore obvious. . .'
and go on from there to matters which may have been obvious to him and God but to no one else."
-- Robert A. Heinlein, character of Daniel B. Davis, 'The Door Into Summer.'

------

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Re: removing exhaust manifold studs
Posted by: ClanDixon ()
Date: October 04, 2019 11:14AM

Here's Davemotohead's video on how to remove them.
How to Remove Stuck Bolts.

Cheers!

Matt
63' Corvair 95 Panel Van
Tampa Bay, FL

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Re: removing exhaust manifold studs
Posted by: Frank DuVal ()
Date: October 04, 2019 06:51PM

Working on Virginia rust cars I gave up years ago trying to remove exhaust manifold studs. Lots of the manifolds here are already smaller in the stud area. Ready to snap off with a little force.

I just cut them flush with the ear, drill a pilot hole of 1/8" right in the center then follow with a 5/16" bit. Then use 3/8-16 tap to make new threads.

I've tried all the other methods, but I find it quicker to just say screw it and cut, drill, tap.grinning smiley

I am speaking of the studs that screw into the exhaust manifold, where the crossover (or U pipes) attach to the manifolds.

Frank DuVal

Fredericksburg, VA

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Re: removing exhaust manifold studs
Posted by: 19sixty5 ()
Date: October 04, 2019 07:07PM

Last time I played with exhaust manifolds was in the late 70's, I ended up drilling and re-tapping Clark's at the time sold replacement stainless steel studs with brass nuts at the time. Highly recommended.

65 Crown Hardtop

Huntsville, AL

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Re: removing exhaust manifold studs
Posted by: RKF ()
Date: October 05, 2019 05:42AM

Frank DuVal Wrote:
-------------------------------------------------------
>
> I just cut them flush with the ear, drill a pilot hole of 1/8" right in the center then follow with a 5/16" bit. Then use 3/8-16 tap to make new threads.
>


How do you locate the exact center of the stud?

Knoxville TN

1962 Corvair Rampside
1963 Corvair Spyder Convertible (project)
1966 Corvair Monza Convertible
1918 Overland Touring Car


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Re: removing exhaust manifold studs
Posted by: MattNall ()
Date: October 05, 2019 08:12AM

Don't forget Davemoto's Hot Wax trick!

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Re: removing exhaust manifold studs
Date: October 05, 2019 08:21AM

That is a great old trick that I have used for decades. I keep a stash of candles in the garage just for that purpose.

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Re: removing exhaust manifold studs
Posted by: Cheepfk ()
Date: October 05, 2019 08:57AM

To me time is money. New or good used replacements are not expensive or difficult to find.

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Re: removing exhaust manifold studs
Posted by: JimBrandberg ()
Date: October 05, 2019 09:49AM

If I drill them out and the holes are big I hit them from both sides with the MIG welder. It doesn't really weld to the cast iron but keeps them from turning or pulling out.
If they're crooked I put 2 nuts on with a space between and use a deep 9/16 socket and long extension to bend after heating red with the torch. I keep a 140 and 110 exhaust pipe collar to check that they will fit well. After all that I usually sandblast them for the good feeling.

I haven't splurged for the $90 + studs + shipping for new Clarks ones yet. I worked on a car that had them, I thought they fit well and were very nice.

Jim Brandberg
Isanti, MN
CorvairRepair.com



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Re: removing exhaust manifold studs
Posted by: Frank DuVal ()
Date: October 05, 2019 10:18AM

Quote
Jim
I keep a 140 and 110 exhaust pipe collar to check that they will fit well.

I do too, to align the stainless studs after I mig weld them to the cast iron manifold when the ears are broken off!

Don't tell me it can't work, you might jinx me!smileys with beer

Quote
Cheep
To me time is money. New or good used replacements are not expensive or difficult to find.

Same here, and keeping a car around while I wait for a western manifold to show up is loosing money when I had the shop going strong. Especially when the repair took less time than ordering replacements.thumbs up

Quote
Roger
How do you locate the exact center of the stud?

When you cut the stud flush with the ear. you have a nice round shiny spot to locate the center. Sure, not always accurate with the center punch or the drill walks slightly never made a jig to fasten one to a drill press.... But the old stud is so well rusted in place, I have had very few ever loosen during this process. West coat non salt people have different results! winking smiley

Frank DuVal

Fredericksburg, VA

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