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[Shagma]

Bottom left side stud was shreded, about 5mm inside the hole.
Tried to drill it out, but of course the drill broke of.
Aparently there were still a some bits of the drill left inside the hole, cos the next drill was unable to hit the center, so without noticing the the hole was moved downwards. It now looks like a keyhole, I would guess its about 9mm "long" and 7mm "wide".
A total nightmare.....!!

But, my first thought was to grind away the remaining material on top of the holde with i minigrinder,almost like a dentist tool.
Then drill it with 8.5mm and tap it with required tap and insert a helicoil M8x1.25

Any other suggestions or inputs is highly appreciated, cos this is really affecting my sleep at night!

[mickfit]

Hi mate
          Was'nt sure if you meant, exhaust to manifold or manifold to engine???
 :-/

[Shagma]

I meant the exhaust manifold mating on the cylinder head.

[ngrainqey]

lol sounds a bit fubar'd to me!

[Shagma]

You gotta keep the faith, keep the faith When the going gets tough..

[ngrainqey]

no...i cant say as i'v ever heard of that one

[G84HAM]

any chance of getting a weld on it, building it up then vice grips?

[hotel21]

Is the stud still proud or flush?  

Placing a slightly oversize nut onto the stud and *carefully* welding the stud to the nut gives you something to hold and work with.  The heat generated from then weld may also dislodge the crap on the threads and allow removal.

Also consider left hand drills but sounds like you have already rubber ducked that option, to be honest.

Orft with its head??  

[Shagma]

The stud was broken inside the hole, about 5mm. This is the reason why I never considered welding..
I do have a drill with allows drilling both CW and CCW. Should I drill CCW ?

I will come back with the result after getting on with the dentist grinder, hope fully manage to get a "clean hole" so I can carry on with the drilling, still 10mm left of the stud in there..

[Shagma]

Alright.. The minigrinder was working out great, it helped to center up the hole again. I managed to get the drilling in the center of the stud again, and to drill the stud all the way through with a 4.5mm drill.
So I drilled it up to 7.5, the stud is gone, but the hole was still not round..
Im gonna look for some serious big time thread inserts..

[Shagma]

For information, the hole was expanded to 10.8mm, then I inserted a threaded insert, self tapping shape, treated with loctite 603. so far so good.
However, after reinnstallation i had troubles finding the correct spot to fit the dipstick pipe? I looks like it should be fitted against the servo pump, or what it is, but I'm not sure!
Anyone?
'97 x20xev