<VV> repairing broken exhaust flange studs?

Tony Underwood tony.underwood at cox.net
Wed Jul 14 01:27:13 EDT 2010

At 09:45 AM 7/12/2010, vair140 at aol.com wrote:

>Are just the studs broken or the ears too?  If only the studs then 
>they can be ground flush and drilled out and replaced with nuts and bolts.

I'm still a fan of welding nuts onto the broken studs and backing 
them out with a box end.    A little heat on the ear helps, and the 
heat on the stud during welding will go a long way to loosening it 
up.   I've done this with not only 'Vair exhaust manifolds but 
smallblock Chevy manifolds and an AMC 6-cyl manifold off a 
Gremlin.   Oh... there was a Pontiac in the mix along the way as well.

Then again, there was a guy named Roger here in town who was good 
enough with a torch that he could burn out a broken stud without 
cutting up the cast iron around it.   I'm not that good, so I weld 
nuts.   It takes a bit of a practiced touch to back a stud out like 
that.   I watched a guy at a muffler shop try it and claim the trick 
was crap after insisting on using an impact wrench on the welded nut 
in spite of being told to wiggle it off with a box end.


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