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Hi gang,
Just a short note to thank all of you that helped
me with giving good advice with regard to the broken exhaust manifold stud of my
60.
Dave, Joe, Chad, Paul, Benjamin, Pete and all the
other that I have forgotten to mention:)
I decided to leave the last broken stud (driver
side, close to the firewall) alone, and try my luck with securing the manifold
with 5 nuts instead of 6.
Well, everything turned out well, no leaks or
whatsoever and the car is as quiet as before.
I will also give Tom Scott a big THANK YOU, for
helping me out with his spare starter motor!
Today I had the car back on the road and it was a
pleasure as always to drive it around town in nice sunny weather :)
Thanks guys!,
Robert
----- Original Message -----
Sent: Thursday, May 10, 2007 10:55
PM
Subject: Re: IML: Problem with exhaust
manifold studs...
Rob, sorry I didn't realize you were "OVER THERE" and not in our back
yard. The reason for thread cutting oil,( which plumbers also use to thread
iron, and galvanized pipe), it has sulfur, and other additives, to reduce
friction, and dissipate the heat from drilling, or taping. Don't use motor oil
or other spray lubes, broken drill bits, and striped taps, will result.Wish
you well, Dave.
--------------
Original message --------------
From: "Rob van der Es"
<R.vdes@xxxxxxxxxxxxxxx>
Thanks again Dave,
I will find me a nice set of fresh Cobalt drils
then :)
Btw, what is the reason for only using thread
cutting oil?
Why not a little WD 40 or light engine oil for
e.g.?
I will ask the machine shop if they know what
an Easy Out is, I never heard of it before nor do I know if they are
available in the Netherlands..
Lucky enough I know for sure where to buy Heli
coils if I need them!
I will make sure to seal the studs with a good
sealer!
Thanks again,
Rob
----- Original Message -----
Sent: Thursday, May 10, 2007 8:27
PM
Subject: Re: IML: Problem with
exhaust manifold studs...
Rob, we've used Cobalt drill bits exclusively, with some cutting oil
as the lubricant.The studs are usually a grade 5, fairly hard, but can be
drilled, with cobalt.Medium speed, with lots of lube.(use ONLY thread
cutting oil)You will have to drill in progressive steps to remove the
stud. There's a chance you can use an "EASY-OUT" if you drill to the
max.The problem with the easy-out is,they tend to expand the the remains
of the stud/bolt, and impead the removal, and if you were to break the
easy out, then there's no hope.If you have to go over-sized on the hole,
use a HELI-COIL insert, seal the studs with Leak-Lock sealer.You can find
it at refrigeration supply houses.That about it, except for
luck.Dave
--------------
Original message --------------
From: "Rob van der Es"
<R.vdes@xxxxxxxxxxxxxxx>
Thanks Dave,
I like the idea of a 90 degree
drill!
I have a dremel and can attach a 90 degree
device to it, and I hope that I can reach the last stud.
Since the studs are heated up and cooled
down so often, will that make the studs softer or harder?
Are there special drills available for this
kind of job then?
I don't know for sure if my skills are good
enough (the only way to find out is trying I am afraid..) but at least I
think that I have the patience.
Have a nice day too,
Rob
----- Original Message -----
Sent: Thursday, May 10, 2007 6:03
PM
Subject: Re: IML: Problem with
exhaust manifold studs...
Rob, all I can say is the out-look is grim.Drilling the studs out
will take patients, and skill, with the drill.
The only way to access the back stud, would be a 90degree
drill, with a helper with a good eye to keep you in proper alignment.
If you choose to use the remaining studs to hold the manifold in
place, keep in mind the manifold uses all the studs to help
transfer the heat from the manifold to the cylinder head. Thats why
there were no manifold gaskets on the manifolds from the factory. The
results may lead to a cracked manifold, or exhaust leaks. In any
event, I don't see an easy fix.Ya'll have a nice day, Dave.
--------------
Original message --------------
From: "Rob van der Es"
<r.vdes@xxxxxxxxxxxxxxx>
> Hi Paul and the rest of
the IML gang,
>
> I need some expert advise with
regard to the exhaust manifold studs of my
> 1960 Imperial.
> For 10 days ago I broke the exhaust manifold flange of the
left manifold...
> I noticed a a roadbump too late and was
hitting it with too much speed,
> since the whole exhaust
system is pretty rigid the impact was given
> directly to the
cast iron manifold..
>
> With the restult that the
flange has broken..
> I found myself a reputable cast iron
welder that has done the job many
> times before so with a
little luck I will have my manifold back early next
> week.
>
> But now for the real problem: when taking the
manifold off two studs were
> bro ken....
> Despite of
several overnight soaking sessions with penetrating oil!
>
> The number two stud (counting from the radiator) and the
last stud are
> broken and almost flush with the head.
> Ofcourse I can try if the 4 remaining studs and bolts will
secure the
> manifold but I simply don't like the idea.
>
> On the otherhand, I either don't like the idea of
taking the head off.
> And at least the last stud is very
difficult (or not..) accessible with
> the head in place.
> So maybe I should aim for the second stud to come out.
>
> Both studs are almost flushed with the head
surface (slightly below
> actually).
> Is there a safe
way to get them out?
> Or should I try to secure the manifold
with the 4 remaining nuts and see
> what happens?
>
> If this doesn't work out, how do I remove those broken
studs then?
> And where can I buy new studs for my engine?
>
> Ofcourse I can try to drill out the number two
studs since I think I can
> access this one from the left
front wheel area (with the left front wheel
> removed
ofcourse).
>
> But what if I screw up and the studs
doesn't come out, since these studs
> are in the cooling
fluid area it is important that I don't cause any
> leakage.
> If I break a drill for e.g. while it is just through the
center of the
> stud (if I am lucky..) and the broken part
gets stuck, cooling fluid will
> escape then!!
>
> So should I go for the 4 studs fasting method first?
>
> Any words of whisdom??
>
> Thanks,
>
> Robert
> 1960 Imperial Crown
>
>
>
>
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