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Stripped exhaust studs


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26 replies to this topic

#1 Markus56

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Posted 14 October 2013 - 06:08 PM

Hey guys hows it going!

 

I've been having problems with my wheeler wagon losing exhaust studs. I need to know how to get them to stick in there. i was thinking about using something like high temp JB weld or something similar, but i dont think it is rated hot enough for exhaust studs.

 

What is going on, is that whomever had this engine before me heli-coiled all of the exhuast stud holes. It is a JDM dual carb EA-81s engine so i believe you have to drill new exhaust holes anyway, because JDM manifolds are 180 degrees off than 'Merican manifolds. 

 

I have a spare motor if it comes to that but i would rather use my fancy engine over a stock one.

 

 

HELP!



#2 capn_r

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Posted 14 October 2013 - 06:23 PM

So you have existing holes with heli-coils? I would consider drilling bolts for safety wire. (Or drilling studs and using castle nuts. Tighten 'em up and wire them to each other around the pipe).

 

 http://en.wikipedia....iki/Safety_wire



#3 Markus56

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Posted 14 October 2013 - 06:27 PM

The helicoils pulled out of the holes, was what i meant, sorry. So i have larger than normal holes i need to make a stud stay in. Also, the original studs are all gone, and every hole seems to be a different thread for some reason.


Edited by Markus56, 14 October 2013 - 06:30 PM.


#4 wagonist

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Posted 14 October 2013 - 07:38 PM

Use bigger diameter studs and retap the holes in the heads?

Obviously drill out the exhaust flange to suit.


Edited by wagonist, 14 October 2013 - 07:38 PM.


#5 scoobiedubie

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Posted 14 October 2013 - 08:19 PM

Move up to 11mm x 1.25

 

Install them in place, with exhaust pipe attached, otherwise you might not be able to get you exhaust pipe on if your new studs are not exactly right.


Edited by scoobiedubie, 14 October 2013 - 08:21 PM.


#6 Markus56

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Posted 14 October 2013 - 08:54 PM

The other problem is that i cannot drill the holes bigger. The walls are already too thin. if i went bigger i would breach the wall of the hole with one right next to it that was drilled by a guy who didn't measure twice. At this point i am looking to use a hardware store grade 8 stud epoxied in place i just cant find an epoxy that has a high enough heat rating,



#7 Uberoo

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Posted 14 October 2013 - 09:38 PM

drill and tap the OTHER bolt holes for helicoils then weld your flanges back 180*.Then get a skidplate so you stop hitting your exhaust manifold on rocks.



#8 scoobiedubie

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Posted 14 October 2013 - 09:56 PM

Used cylinder heads are cheap from the junk yard. Then you don't have to put in all that work, and possibly fail.

#9 Markus56

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Posted 14 October 2013 - 10:05 PM

Used cylinder heads are cheap from the junk yard. Then you don't have to put in all that work, and possibly fail.

 

These are dual carb heads. you will NEVER find them anywhere. not to sound like a jerk, but I really cant replace them.



#10 Markus56

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Posted 14 October 2013 - 10:08 PM

drill and tap the OTHER bolt holes for helicoils then weld your flanges back 180*.Then get a skidplate so you stop hitting your exhaust manifold on rocks.

 

You mean to cut the flanges off and re-weld them?



#11 Markus56

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Posted 14 October 2013 - 10:10 PM

Do you guys think something like this would work? I read an Amazon review where a guy drilled and tapped it, but i would just want to permanently fix some studs in there.


Edited by Markus56, 14 October 2013 - 10:15 PM.


#12 Leeroy

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Posted 14 October 2013 - 11:36 PM

Why not use Timeserts or Bigserts? These work far better than helicoils IMO (they do not tend to unscrew) and are easy to install once you have the install tool.

 

http://www.timesert.com/index.html



#13 NorthWet

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Posted 15 October 2013 - 12:31 AM

A more permanent, if more involved, solution is to have a machinist fill-weld the current holes and retap them.



#14 86 Wonder Wedge

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Posted 15 October 2013 - 10:55 AM

A more permanent, if more involved, solution is to have a machinist fill-weld the current holes and retap them.

 

Bingo.

 

If the heli-coils have pulled out already, then going to something bigger wouldn't be the best idea. Have the metal replaced then drill and tap. Best way to go. Do you still have the bracket welded after the converter that anchors to the transmission?



#15 scoobiedubie

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Posted 15 October 2013 - 11:42 AM

 

These are dual carb heads. you will NEVER find them anywhere. not to sound like a jerk, but I really cant replace them.

 
This guy will have them.
http://portland.crai...4094892510.html

And if he doesn't have them, then these guys will:

Mountain Tech Subaru
Oregon City, OR
503-650-3686
http://www.mttechsuba.com/

Edited by scoobiedubie, 15 October 2013 - 11:47 AM.


#16 Uberoo

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Posted 15 October 2013 - 03:15 PM

You mean to cut the flanges off and re-weld them?

yes.Unless dual carb heads are different, Ea81's have 4 holes around the exhaust for various markets.Two of them are normally unused.So just rotate the flanges and use the other holes..



#17 scoobiedubie

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Posted 15 October 2013 - 09:08 PM

How about change out both the cylinder heads and the intake manifold, with the American set?

#18 Leeroy

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Posted 16 October 2013 - 12:11 AM

yes.Unless dual carb heads are different, Ea81's have 4 holes around the exhaust for various markets.Two of them are normally unused.So just rotate the flanges and use the other holes..

 

Dual carb heads only have two holes/studs for the exhaust header, not four.



#19 Leeroy

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Posted 16 October 2013 - 12:22 AM

There are pics on this forum:

 

http://www.rotaryfor...ead.php?t=13716



#20 Markus56

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Posted 16 October 2013 - 07:56 PM

How about change out both the cylinder heads and the intake manifold, with the American set?

 

Dual carb head are only work with a dual carb block, as the valves are backwards, and because of that, it uses a different camshaft. Also there are no reputable machine shops within 250 miles of where i live that i know of. I really think that some sort of epoxy is my best bet at this point, I am just not sure.

 

Also, to have the holes filled back in, i would have to remove the heads, right?



#21 wagonist

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Posted 16 October 2013 - 08:21 PM

Are there spots where you can see that the other 2 holes would be?

You could drill & tap those. But it would mean removal of the heads and accurately drilling & tapping them.



#22 Petersubaru

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Posted 16 October 2013 - 08:35 PM

Hey guys hows it going!

 

I've been having problems with my wheeler wagon losing exhaust studs. I need to know how to get them to stick in there. i was thinking about using something like high temp JB weld or something similar, but i dont think it is rated hot enough for exhaust studs.

 

What is going on, is that whomever had this engine before me heli-coiled all of the exhuast stud holes. It is a JDM dual carb EA-81s engine so i believe you have to drill new exhaust holes anyway, because JDM manifolds are 180 degrees off than 'Merican manifolds. 

 

I have a spare motor if it comes to that but i would rather use my fancy engine over a stock one.

 

 

HELP!

Since there are 4 holes on the head ..I went to a muffler shop and had them cut and twist the flanges to mate with the other 2 holes..the cuts were welded back up with a new center piece covering the entire part that was cut..double up with the gaskets and some high temp silicone between them....has lasted for many years now...use studs and nuts...



#23 Leeroy

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Posted 17 October 2013 - 01:39 AM

Since there are 4 holes on the head ..I went to a muffler shop and had them cut and twist the flanges to mate with the other 2 holes..the cuts were welded back up with a new center piece covering the entire part that was cut..double up with the gaskets and some high temp silicone between them....has lasted for many years now...use studs and nuts...

 

 

There are only 2 holes in a dual carb head not 4...

 

ExhaustPorts.jpg



#24 ivans imports

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Posted 17 October 2013 - 09:53 AM

if you are very carefull can drill about a 1/8 deeper to get threads below the damaged threads but i whould jump up to a 7/16 standard thread hili coil



#25 scoobiedubie

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Posted 17 October 2013 - 10:59 AM

 

if you are very carefull can drill about a 1/8 deeper to get threads below the damaged threads but i whould jump up to a 7/16 standard thread hili coil

 
What happened to keeping it all metric?




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