Completely rounded exhaust studs

Gazdaman · I did a trackday!!! Joined: 12 Aug 2004 Karma :

Not a problem at the moment, but I'm sure at some point they'll need replacing as they're fairly crusty.

I had a peek at them today and they are completely round. I think they used to be hex bolts as they're round both on the inside and the outside.

What's the best way of getting them out? I might give them the penetrating oil, some heat and hope mole grips do the trick but obviously the bolts aren't easily accessible.

Very tempted when I get some new downpipes are just to drop it off at a dealer and tell them to 'deal' with it.

I could drop the engine, drill them out, and get the studs extracted locally.

I can't see the mole grips working.

So, any bright ideas anyone?

Gaz

---- · World Chat Champion Joined: 29 Sep 2006 Karma :

You'll be suprised how well mole grips will work,if you've got a decent one...Use plenty of heat! and lots of wd40 every day for a few days before tackling it...

Thumbs Up

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DRZ-400sm

ms51ves3 · Super Spammer Joined: 07 Jun 2007 Karma :

Hacksaw a slot into it and use an impact wrench but I'm not sure if that would be the best method.

djaaron · Derestricted Danger Joined: 27 Jul 2008 Karma :

seen this happen a lot i use a welder and weld a nut on the end

Gazdaman · I did a trackday!!! Joined: 12 Aug 2004 Karma :

That's an option. I don't have a welder though.

The thing is, if I attempt this job, I need to finish it. I can't afford to snap a stud, because it's my transport to work.

That's why giving it to someone and saying 'sort it' is an attractive option.

Gaz

quik_d · Could Be A Chat Bot Joined: 17 Mar 2005 Karma :

my exhaust bolts were a bit iffy, but you can get these sockets that kinda cut into the bolt head and effectively tap it, then when you wind it out to undo it they grip onto the head and hey presto tends to work

in addition to this for a few days before removal to sprayed copious amounts of wd40 which helped i think
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LOOK AT DAT M8 WELL LUSH A PARROT INT IT

Bezzer · World Chat Champion Joined: 14 Apr 2005 Karma :

Suzuki header bolts are usually M8 and the best removal method is to get a 12mm multipoint socket- 3/8ths or 1/4" drive whichever you can get in- and hammer it over the bolt head. 12mm is spot on for the socket grooves to bite into an M8 allen bolt head outer edge then connect and use a ratchet to unscrew it. Give them a soaking in PlusGas the day before to give it more of a helping hand.
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I used to be indecisive but now I'm not quite so sure.