October 20, 200916 yr I tore my exaust out last week, and I went to fix it today, I tried the Heli coil kit first bit that went south quick, then I tried to tap it out a little more, I now have the hole up to a 1/2" and I think I screwed up those threads too.................................. Has anyone used JB weld in the hole before and had it work? I think I'm running out of options other than replacing the head................... Any Ideas would help............... Jeff
October 20, 200916 yr Hmm, Well I know JB-Weld will just burn off. I tried to fix my downpipe with it before the new one. it last for like 2 miles and then started to burn. it held somewhat but it won't last. You figure that head gets close to 800 deg F at times. What about cleaning around the hold with evory cloth and then tac the stud in place? 2 tacs should be enough to hold it with out fail. Other then getting a new head I think your SOL. Maybe, this is USMB! Anything is possable Best of luck, -Tom Lemme know what you think of tac welding it in place.
October 20, 200916 yr well if its EA82 you have 4 holes to choose from.. run new studs in the empty holes that were never used. they are pre-threaded. cut your pipe about an inch or inch and a half down from the flange and rotate 90 degrees and weld the pipe back in place.. Now you have brand new threaded holes that have never been used. Do yourself a favor and use high temp anaerobic sealer on the new studs your putting in. Done deal brand new exhaust studs/holes etc.. BTW - #1, JB weld wont work it will burn off and it stinks like poop when it burns. #2, You arent going to "tac" weld steel to aluminum
October 20, 200916 yr Author Lemme know what you think of tac welding it in place. I'm going straight in the aluminum head and the bolt is Steel........... can't weld that.......... Jeff
October 20, 200916 yr Duh, god! See what happens when ya been up since 9am and its now 12:30am. ya start putting out dumb ideas Lol. Ok forget the tac welding thing Lol.. Torxxx, Yes this is a good idea! I noticed the other set of stud holes on the heads when I changed out the y-pipe before. Great idea! Jeff, I would find the proper tap and just chase the new threads just so there is no build up of dirt in the holes so the new studs go in nicely. you prolly knew this. -Tom
October 20, 200916 yr Author well if its EA82 you have 4 holes to choose from.. run new studs in the empty holes that were never used. they are pre-threaded. cut your pipe about an inch or inch and a half down from the flange and rotate 90 degrees and weld the pipe back in place.. Now you have brand new threaded holes that have never been used. Do yourself a favor and use high temp anaerobic sealer on the new studs your putting in. Done deal brand new exhaust studs/holes etc.. BTW - #1, JB weld wont work it will burn off and it stinks like poop when it burns. #2, You arent going to "tac" weld steel to aluminum Its an EA82 car with an EA81 in it, The other tow holes where for the evironmental stuff, the Steel spacer blocks, they are what broke, there are bolts broke off in the heads where they are supposed to be, I only have one option for holes, and thats the way the exaust bolts up....... Jeff
October 20, 200916 yr Oh its a EA81, is this in your main rig? I thought you ran a EA82 in it? Hmm, damn the 2nd set of holes was a good idea too. There has to be a better way to fix this then replacing the entire head! What about drilling new holes and threading them? Possable, Dunno if there is room for two new holes? -Tom Edited October 20, 200916 yr by TheLoyale
October 20, 200916 yr If it were me, I would probably get some 1/2" all-thread (or grade 2 bolt), cut a peice slightly longer than the hole is deep with a slot for a screwdriver in it, loctite that sucker in place, grind it flat and drill/retap it to the correct size. Either that or if you have access to a TIG welder and know someone's that good with overhead aluminium you could have them fill the hole.... but that's probably a tall order. How is it that you keep screwing up the threads? Are you trying to run the tap with a crescent wrench or something? Get a proper tap handle and have a little care man! GD
October 20, 200916 yr Jeff, do you have to pass emisions in that car? If not, just take off the cast iron spacers and use an EA82 Y-pipe, and cut the flange to rotate it 90 degrees and use the other pair of holes. I always take those stupid spacers off my EA81's. -Bill
October 22, 200916 yr I've done a couple different things in the past. The best thing I did was TIG weld some new studs into the heads, cleaned up the welds with a scream reamer (or a Dremel with a grind wheel if you use electric) and voila done. Other thing I did was what GD said. I drilled it out to accept a 1/2"x20 thread, used loctite on the threads of some all thread, screwed it in there using the double nut system, cut the studs off, made the gasket surface flat, center punched the now steel inserts, drilled, tapped and put factory studs in.
October 22, 200916 yr I have tapped OS, drilled a bolt, tapped that, screwed it in, cut it off flush with the head, and run my exhaust bolt into that - essentially made my own 'time cert', a threaded steel sleeve for the galled holes in the aluminum. I did it all by hand, (air tools) but no drill press or lathe. It's held up fine and I've had my exhaust off twice since then without having and problems of my insert backing out, or the threads weakening. Not a super hard thing to do, but labor intensive. .02
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