Broken Maniflod Stud
 

Is it possible to get out a broken exhaust manifold stud at home, or do I have to take it to a machine shop? Thanks.

Lucky there is still some stud there. What I have seen by the toolmakers and millwrights at work, is to clean off the part thats there with wire brush. Then they take a nut of the same size of the stud, place it over it and puddle-weld the stud and nut together. This makes it almost like a new bolt! Plus the heat from the welding will expand the bolt and then contract it after cooling. Possibly helping to work it loose. Good luck.

Since it is on a slant 6, I would also remove the thermostat housing to give yourself a little extra room.

Here ya go! Video how to. http://www.ehow.com/video_2327766_re...g-welding.html :D

good fricken luck...lol..i had that problem on my sport fury's 318...tried a few different ways to get it out.

1st i tried the weld a nut thing and broke it off down inside the head...then i went to trying to drill it out...tried to torch it out and finally went to an extractor. long story short....ended up breaking the extractor off inside the head and said f it.
since i get one hell of a discount at work..i just replaced the heads with remans. i figured our local machine shops wanted about $120 bucks per head to fix my mistake and rework the heads....i got complete reman heads for about $30 per more.
from what ive heard from ppl...its a common problem since the 2 end studs are a water passage or something like that ...that they corrode really badly and pretty much fuse themselves to the head.

Welding the nut to the stud is genius! Took a couple tries but was successful...thanks to all :D

good job