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Old 10-12-2017, 11:50 PM   #1
maxitoman007
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Default Seal turbo exhaust header without a manifold stud

So I broke off a manifold stud while I was trying to tighten it down. And it won't come out. I've tried drilling it out but I just can't get it to work. I'm starting to wonder if the manifold will still seal properly enough to run around 20 lbs of boost without a manifold stud there. Has anyone done this?
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Old 10-12-2017, 11:58 PM   #2
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have you tried to weld a nut over the stud then take it off with a socket or wrench?
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Old 10-13-2017, 12:05 AM   #3
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I've tried everything, you don't want to see what it looks like now, just a big deep hole with no sign of the stud ending or where the head begins. It's a true mess. I've broken off all kinds of things in there. Honestly I'm just preying someone will tell me it'll seal ok without it so I can stop working my butt off only seeming to make it worse. It is a middle stud tho so maybe the manifold being pressed against the head on either side will seal it?
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Old 10-13-2017, 12:39 AM   #4
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Sounds good to me, but I can't see it from my back yard...
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Folks on here don't know a good deal when they see it.
how psi a stock can support?

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Old 10-13-2017, 12:47 AM   #5
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What? You think it'll seal?
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Old 10-13-2017, 12:49 AM   #6
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My machinist just told me to spray engine paint on the turbo to manifold metal gasket, said it would get rock hard. But I don't think it will help your situation, it's not going to seal without the fastener there. Install a 10mm timesert and drill out the manifold and the gasket.
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Old 10-13-2017, 01:34 AM   #7
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I say give it a try, maybe with some copper RTV or something. At the worst you'll have a ticky exhaust until you find a new head, right?
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Old 10-13-2017, 01:45 AM   #8
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Finally someone who supports me lol. My question is will it affect boost? Like can I still hit 20 psi or will the leak mess it up. Will it just spool a bit slower?
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Old 10-13-2017, 01:52 AM   #9
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Try using Würth exhaust paste or something similar. You want a sealant that turns hard and can deal with super high temps. RTV will just melt and blow out. Not even worth trying. If you can get the seal to hold without an exhaust leak then it might hold up to boosted use. Remember that combustion pressures are much higher than the 20psi of boost you're adding.
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Old 10-13-2017, 02:17 AM   #10
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Quote:
Originally Posted by 77volvo245 View Post
have you tried to weld a nut over the stud then take it off with a socket or wrench?
Best way that actually works






Op weld vice grips to the manifold then clamp it down tighter when it starts to leak because it will leak. Then weld vice grips to those vice grips
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Old 10-13-2017, 02:22 AM   #11
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Just weld the manifold to the head. It'll never leak.
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Old 10-13-2017, 02:24 AM   #12
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Oh ok, any good products you know that would be available at a local hardware store (like permatex something)? Also I have 2 exhaust gaskets and I don't know which to use. One of them is four individual gaskets (one for each exhaust port) which I believe is better quality as it came with the head rebuild kit, but I also have a one piece gasket that came with me ebay exhaust heade (lower quality I believe). I'm worried that using the 4 separate gaskets will lead to the gasket blowing out on the port missing the stud as it will only be secured at one point whereas the ebay gasket could sit on all the othe studs. would the compression from the manifold hold the individual gasket in place? But I also don't want to use the cheap eBay gasket.

I think I have come to the conclusion that the hole where the stud was is so mangled that my only options are: new head or run it and pray. And my wallet only supports one of those options...
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Old 10-13-2017, 02:36 AM   #13
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You’re faked. Don’t spend your money on magic shmoo. Talk to your local machinist. Bring pictures


Then when you get the head fixed and install that Chinabay header it will leak anyway




Hmm. I take it back since you will get leaks no matter what, run as is
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Old 10-13-2017, 11:51 AM   #14
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It might make an annoying sound but it'll be fine. I actually ran an na b230 with a broken stud and it somehow didn't leak...
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Old 10-13-2017, 12:21 PM   #15
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Just get a replacement head. Pay now or pay later.
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Old 10-13-2017, 12:40 PM   #16
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Get a really big self tapping screw
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Old 10-13-2017, 12:50 PM   #17
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Take it to the machine shop, get it fixed.
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Old 10-13-2017, 12:54 PM   #18
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Quote:
Originally Posted by maxitoman007 View Post
Finally someone who supports me lol. My question is will it affect boost? Like can I still hit 20 psi or will the leak mess it up. Will it just spool a bit slower?
I don't think it will leak enough exhaust to make much of a difference. But you may not care for the noise from the exhaust leak.
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Old 10-13-2017, 01:12 PM   #19
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Is the stud broken off in the head or the manifold itself? Sounds like the manifold.. doesn't much matter except when drilling the head you have to make sure to not go too deep as to hit a water jacket or anything like that. Having trouble visualizing the cooling system in a 530 right now.

Drill the broken stud all the way out, nice and clean, then re-tap the empty and threadless hole to a larger size and get a "step" stud. Not sure on factory sizing but you can get a m8 to m10 stud cheap.

I semi-recently put all new exhaust manifold studs in a V10 ford, used a LOT of acetylene with an occasional oxy blast to blow out chunks of steel. We mostly used step studs because several broke off inside the head. (vehicle had been driven into the water in Ocean City MD by a PO)

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Old 10-13-2017, 01:59 PM   #20
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Timesert kit. I went through a similar situation on my red car with the alternator bracket bolt into the block. Timesert fixed it very well.
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Old 10-13-2017, 04:31 PM   #21
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I once wanted to remove studs on a Mitsubishi housing. They snapped , and I destroyed all my drill bits getting the threaded bits out ( and I know how to sharpen drill bits )
OP , please let a machinist shop of some kind help you out.......!
Why do people in the US always think you can fix serious problems with something from a bottle or can ?
You want to upgrade the performance/car right ?
Trust me , you dont start doing this by using a leaking exhaust anywhere in the system
Do less , but do it properly......
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Old 10-13-2017, 04:33 PM   #22
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Sorry , I should have said SOME people in the US !
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Old 10-13-2017, 04:39 PM   #23
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Honestly I think the mangled hole I've made is too off centered for even a large time sert to work. Not to mention I have barely any funds to work with. I literally just replaced the head gasket so I don't really want to pull the head again. It's getting cold here in Alberta and all I have is a garage. Manifold surface is around 1/2 an inch thick so I don't think it'll warp when trying to install just have to tighten down the studs on either side enough to push it down right? The car is honestly zero f****s given and I'm tired of putting money in. As for the exhaust leak, the pipe is coming out the hood anyways...
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Old 10-13-2017, 05:17 PM   #24
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Oh yeah hood pipe, I forgot, skip every other fastener
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Old 10-14-2017, 10:26 AM   #25
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Think I'm going to go with some exhaust repair/assembly paste. Should seal it up good enough
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