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[mike9570]

about to start the process of drilling out and replacing the exhaust manifold studs, 3 studs broken flush with the head, question is how deep can i drill. it looks like ive got about 1cm of stud remaining in the head is this about right if broken flush. and is there any water/oil ways close to ex/port 1.  :-/

[Matchless]

IIRC, there is a waterway behind one of the front studs, the hole doesnt go right through into the water way but there is very little alloy left so its easy to break through.

Are you using a pillar drill or hand held? On pillar drill set a depth stop from one of the other holes. On a hand held you can attach a collar to the drill bit to act as a depth stop or wrap some insulation tape around the drill bit.

Take extra care to find the stud centre, the stud WILL be stuck in the threads so easy-outs etc dont tend to work. Creep up in drill size (0.1mm steps if you have them) until you you are fractionally below the thread root then try a small punch on the tip of the remaining thread, tap the thread tip inwards into the hole. If you are properly centred then you should be able to get hold of the end with pin-nose pliers and pull the thread out like a long spiral. This method leaves the threads completely un damaged but depends on accurate centreing.

Put a smear of copper grease on the new studs before winding them in with two nuts locked on the thread.

[mike9570]

just finish putting all back together ,no point trying to drill them out, the head is fkuced the last owner made a right mess,  
so i think a new head is going to be fitted..