Exhaust - Nuts Totally Corroded!
#61
Ok, I've just gone for the welded-nut method
Waste of time, It did absolutely nothing
So, It looks like Stef's solution is next
Stef - I'm looking at the various bushes available, trying to decide which size to purchase
I can only get a 5mm bush with an 8mm outer diameter, which is too small for the 10mm hole in the manifold
If I get a bush with an outer diameter of 10mm (to match the manifold) I can choose from a variety of inner diameters ranging from 5.10mm to 6mm (in increments of 0.1mm)
I'm thinking if I go for the 5.1mm diameter bush the 5mm drill might wander around inside it too much
If I go for the 6mm diameter bush, will that leave too big of a hole to then tap a M8 thread?
Thanks again Stef
Waste of time, It did absolutely nothing
So, It looks like Stef's solution is next
Stef - I'm looking at the various bushes available, trying to decide which size to purchase
I can only get a 5mm bush with an 8mm outer diameter, which is too small for the 10mm hole in the manifold
If I get a bush with an outer diameter of 10mm (to match the manifold) I can choose from a variety of inner diameters ranging from 5.10mm to 6mm (in increments of 0.1mm)
I'm thinking if I go for the 5.1mm diameter bush the 5mm drill might wander around inside it too much
If I go for the 6mm diameter bush, will that leave too big of a hole to then tap a M8 thread?
Thanks again Stef
Make sure that you grind the remaining part of the bolt nicely flat. The flange is 12mm thick and the bushing is 10mm long so the broken bolt might stick out just a little bit.
#63
Update - Or not?!
It's been a week and i'm still waiting for my drill bush to arrive!!!
I paid £4.34 for the bush
They charged me £6.00 postage!!!
And then charged me tax on the postage too
So I've paid £7.20 postage on a £4.34 part, which still hasn't arrived after a week!
NOT HAPPY
It's been a week and i'm still waiting for my drill bush to arrive!!!
I paid £4.34 for the bush
They charged me £6.00 postage!!!
And then charged me tax on the postage too
So I've paid £7.20 postage on a £4.34 part, which still hasn't arrived after a week!
NOT HAPPY
#67
I've run a grinder over the studs do they're flush with the head
Next job is to enlarge the holes in the manifold in order to press the bush in place
The only problem with that is the ****ing manifold is harder than the drill bits are!!
So far I've ruined three drill bits
I've rounded two of them, and snapped the third one
God alone knows what Porsche made these manifolds out of
Anybody know how to remove a snapped HSS drill bit from a manifold flange?!?
Next job is to enlarge the holes in the manifold in order to press the bush in place
The only problem with that is the ****ing manifold is harder than the drill bits are!!
So far I've ruined three drill bits
I've rounded two of them, and snapped the third one
God alone knows what Porsche made these manifolds out of
Anybody know how to remove a snapped HSS drill bit from a manifold flange?!?
#68
I've run a grinder over the studs do they're flush with the head
Next job is to enlarge the holes in the manifold in order to press the bush in place
The only problem with that is the ****ing manifold is harder than the drill bits are!!
So far I've ruined three drill bits
I've rounded two of them, and snapped the third one
God alone knows what Porsche made these manifolds out of
Anybody know how to remove a snapped HSS drill bit from a manifold flange?!?
Next job is to enlarge the holes in the manifold in order to press the bush in place
The only problem with that is the ****ing manifold is harder than the drill bits are!!
So far I've ruined three drill bits
I've rounded two of them, and snapped the third one
God alone knows what Porsche made these manifolds out of
Anybody know how to remove a snapped HSS drill bit from a manifold flange?!?
Re-coil inserts done properly will last forever. Go on the tinternet and have a look at them. The kits come with the required drill and taps and a number of inserts.
http://www.recoilshop.net/?gclid=CM_...FQUNfAodTnQnMw
Last edited by Frank ( Sunnyside ); 12-04-2011 at 08:47 AM.
#69
Hi Ant
I am just about to do the same as you, my Actuator rod has broke, all the turbo nuts
are corroded away to practically nothing, the oil pipe connections look fubared too. I
am particularly worried about removing the Exhaust bolts as they are rusted as well, looking at possible problems to come that drill guide looks promising.It will be interesting to hear how you get on removing the bolts, I have been told by someone to heat up the bolts before removing and also to give them a sharp knock with a hammer first, I will of course be getting in touch with Frank to ask his advice about my getting my Turbo!s repaired anyway good luck with the rest of the dismantle
Max
I am just about to do the same as you, my Actuator rod has broke, all the turbo nuts
are corroded away to practically nothing, the oil pipe connections look fubared too. I
am particularly worried about removing the Exhaust bolts as they are rusted as well, looking at possible problems to come that drill guide looks promising.It will be interesting to hear how you get on removing the bolts, I have been told by someone to heat up the bolts before removing and also to give them a sharp knock with a hammer first, I will of course be getting in touch with Frank to ask his advice about my getting my Turbo!s repaired anyway good luck with the rest of the dismantle
Max
#70
Thanks mate
I haven't actually got that far yet though!!
What I've been trying to do is drill the manifold itself
The bush that Stef recommended is a push fit inside the manifold holes
The bush is 10mm OD, whereas the manifold holes are ~9.5mm, meaning they need enlarging slightly in order to press the bush home
The problem with that is the manifold is ludicrously tough, as you can tell from my drill bits!
I'm confident about drilling the studs in the head (when I eventually get to that part) as they seem to be made out of cheese!
But before I can do that I need to tackled this manifold
I'm thinking I'll take the manifold to a shop tomorrow to get the holes drilled
In the meantime, I'm going to refit the rightside manifold, as that one's ready to go
That way I'll feel like ive at least made some progress
I haven't actually got that far yet though!!
What I've been trying to do is drill the manifold itself
The bush that Stef recommended is a push fit inside the manifold holes
The bush is 10mm OD, whereas the manifold holes are ~9.5mm, meaning they need enlarging slightly in order to press the bush home
The problem with that is the manifold is ludicrously tough, as you can tell from my drill bits!
I'm confident about drilling the studs in the head (when I eventually get to that part) as they seem to be made out of cheese!
But before I can do that I need to tackled this manifold
I'm thinking I'll take the manifold to a shop tomorrow to get the holes drilled
In the meantime, I'm going to refit the rightside manifold, as that one's ready to go
That way I'll feel like ive at least made some progress
#71
Max, I'll take some pictures of the rest of my exhaust nuts for you
They're a ****ing joke
I can't believe how much must have been spent on the manifolds (seriously, you can't drill through them they're that tough) but then they go any use the ****tiest cheapest fixings possible
They're a ****ing joke
I can't believe how much must have been spent on the manifolds (seriously, you can't drill through them they're that tough) but then they go any use the ****tiest cheapest fixings possible
#72
Ant
Sorry I posted before your latest debacle, I feel for you mate looks like the manifolds are the only tough bit on the car it really is a rust fest under mine take heed of Frank he has been through all this a more
Max
Sorry I posted before your latest debacle, I feel for you mate looks like the manifolds are the only tough bit on the car it really is a rust fest under mine take heed of Frank he has been through all this a more
Max
#73
You may need cobalt bits that are stronger to get thru the manifold. And then need a drill press to get thru it. Here, correct speed and lube/coolant is important. I hope you're right about the studs being soft. Generally they are a grade 8 equal in hardness and the drill bits will just roll off. If they are hard as well, you'll need to start with a colbalt number 60 or so, very small and work upwards. In this case the bushing will need a reducer pressed in to center successive smaller bits. The problems are just starting, I've been there many times, do this stuff for a living and have since the '70s. I would have exhausting all attempts and efforts welding before attempting drilling. Sorry if it's too late, but I did mention this earlier. At any rate, GL!
#74
Thanks Nick
I tried the welding route but had no joy
I'll be fitting a 5.5mm bush in the manifold flange and will drill a small hole into the studs in the head
The plan is to then retap the thread in the head with an M8
I think with the smaller sized bush being used first, and only being used as a pilot hole it shouldn't be too bad
Having said that, everything has gone wrong so far, so I'll probably have problems there too!
I tried the welding route but had no joy
I'll be fitting a 5.5mm bush in the manifold flange and will drill a small hole into the studs in the head
The plan is to then retap the thread in the head with an M8
I think with the smaller sized bush being used first, and only being used as a pilot hole it shouldn't be too bad
Having said that, everything has gone wrong so far, so I'll probably have problems there too!
#75
You may need cobalt bits that are stronger to get thru the manifold. And then need a drill press to get thru it. Here, correct speed and lube/coolant is important. I hope you're right about the studs being soft. Generally they are a grade 8 equal in hardness and the drill bits will just roll off. If they are hard as well, you'll need to start with a colbalt number 60 or so, very small and work upwards. In this case the bushing will need a reducer pressed in to center successive smaller bits. The problems are just starting, I've been there many times, do this stuff for a living and have since the '70s. I would have exhausting all attempts and efforts welding before attempting drilling. Sorry if it's too late, but I did mention this earlier. At any rate, GL!
Nick's right you must use cobalt drills. "Assumption is the mother of all **** up's" and I assumed you were using Cobalt drills. you must spend the little extra and get a set from 1mm to 5mm. I haven't used those steel drill inserts, I just took the bull by the horns and drilled slowly and accurately. I didn't even have to use Recoils, however I knew they were there just in case. ( this wasnt on the head btw, I was lucky i got mine all out......but only just and was very very lucky.)