<VV> Need some shop advice on exhaust studs

FrankDuVal corvairduval at cox.net
Mon Nov 9 22:41:04 EST 2020

Well, Dave Motohead has a nice video, but he lives in the make believe 
world of rust free cars in California, so wax does work for him. Just 
look at the exhaust manifold in the video, look brand new compared to 
our east coast rusted manifolds. Why, even the ear is full size!

Here in the rusty east, I have developed a fool proof method of removing 
exhaust studs. I did NOT say easy.

Remove manifold from engine.

Mount manifold in sturdy bench vise with the flange up. As level as 
possible so you can align the drill plumb.

Cut bad stud off flush with ear.

Center mark as well as you can the fresh cut stud.

Drill through with a 1/8" bit.

Drill through with a 5/16" bit.

Tap for 3/8-16 new stud.

Yes, sometimes the method will unscrew the old stud, but not usually. I 
do not even try to use an Easy-Out, left handed drill bit, or other stud 
removing methods. I've wasted too many hours dealing with removing and 
then having to drill and tap anyway. I've worn down many 5/16" bits over 
the years. I am good at resharpening with a bench grinder. Sharp is 
good, dull will drive you nuts and waste your time. Slow Speed! Lots of 

I put in the stainless steel studs as replacements. And brass nuts. Use 
lock washers, as brass on stainless steel will not stay!


Osn 11/9/2020 5:20 PM, Grant Young via VirtualVairs wrote:
> I need to drill out an exhaust log stud(s), but am not having much luck. Just looking for advice on the type of drill bit and any thing else or procedure needed. Thanks,
> Grant

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