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Drilling Broken Exhaust Stud. 17/64 or 8mm cobalt drill bit? 200 1984

posted by  Roadside Mechanic on  Mon Feb 11 09:58 CST 2008
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last visit: Fri May 23 13:40 CST 2008
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Hi Folks.
CX thanks for the replies. So the removal of the stud did not go that well. The bright side is that the hole is straight, but now my choices are a 17/64 th bit or an 8mm bit? I am going to re-tap the hole with a flat bottom tap. I have light cutting oil, and I am going to turn it less than a 1/4 turn, applying cutting oil. I am not sure if with the 17/64 that it leaves more aluminum or what. Again thank you all in advance, for your help.

Chad








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    Drilling Broken Exhaust Stud. 17/64 or 8mm cobalt drill bit? 200 1984

    uid 39111's pic
    posted by  Kenner on  Mon Feb 11 12:40 CST 2008
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    last visit: Sun Aug 24 15:42 CST 2014
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    Whatever the size is, the key is patience and a steady hand. I drilled 2 out last year. Engine in the car. Borrowed my mechanic buddies right angled Blue Point air drill. I bought three top end drill bits 1/4 ' and up (i think) 2 5/16 taps one starter and one bottom and away i went. Patience my friend patience. Especially when tapping. That was 25,000km ago and all is well. I hope to never do it again. Good luck.
    --
    420,000KM and still ticking








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      Drilling Broken Exhaust Stud. 17/64 or 8mm cobalt drill bit? 200 1984

      posted by  Roadside Mechanic on  Tue Feb 12 04:20 CST 2008
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      last visit: Fri May 23 13:40 CST 2008
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      Thanks Kenner. The idea about patience is great, and it leaves the impression of taking this very slowly and that it can be done. Thank you.








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    Drilling Broken Exhaust Stud. 17/64 or 8mm cobalt drill bit? 200 1984

    posted by  walrus3 on  Mon Feb 11 12:31 CST 2008
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    last visit: Mon Dec 2 14:20 CST 2013
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    8mm is 0.315" 17/64" is 0.266. If the bolt is 8mm an 8mm drill will drill
    all the threads out of the hole. Tap drill size for 5/16"-18UNC is an "F"
    drill which is 0.257" and the threads are only SLIGHTLY bigger so I would
    stick with 17/64 or maybe slightly smaller. A "G" drill is 0.261" and would
    probably be an appropriate tap drill. You might want to start with a ΒΌ" (0.250")
    drill and see how it goes.
    All the above is based on the stud being 8mm. If it is a smaller size (6mm)
    you will ruin things with either drill.
    --
    George Downs, Bartlesville, Heart of the USA!








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      Drilling Broken Exhaust Stud. 17/64 or 8mm cobalt drill bit? 200 1984

      posted by  Roadside Mechanic on  Tue Feb 12 04:22 CST 2008
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      last visit: Fri May 23 13:40 CST 2008
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      Thanks Georege. I saw all those different sizes around, but i needed clarification. I thank you and it is off to the hardware store. Many Thanks.

      Chad








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        Drilling Broken Exhaust Stud. 17/64 or 8mm cobalt drill bit? 200 1984

        posted by  jimjmorris on  Tue Feb 12 14:46 CST 2008
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        last visit: Mon Sep 29 19:45 CST 2014
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        Chad,
        A little advice. Wear eye protection. Get a good full face shield if you do this with it still in the car. I spent an evening, new years eve, in the ER having them fish bits of manifold stud out of my eye, all due to a few pieces going in from under my safety glasses.

        You can drill it out completely and not re-tap it. Just put a stainless bolt through the hole (or regular bolt) and use that. It will work. Dad's car is just dandy now with that arrangement.

        Patience is the key. Took me 4 hours to drill it out completely.

        Jim







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