UKSaabs

found this example of a jig for drilling out a broken stud or the head ready to accept a heli-coil..............bit OTT but looks good

Hello All

Really this is a commom problem in Saab models

In last month i took all the studs from a 9-3... grrr... (some in 9000 too...)

worse, i thing, is when they broke on turbo... like this onde:



I was looking for studs with better corrosion resistance. I readed about stainless studs, but they keep all the hot and then they "glue" to the metal... especially on turbo (forged steel on turbo and stainless on studs)

The solution i found was tu use galvanized studs.

First they are protected against corrosion, and then, because they are protecte with another metal layer if they "glue" we just need to take them out because this layer will break.
So they are protected and they dont break if they are "glued".

See example:


To prevent them to "glue" i used termic copper paste, it protects until more than 1000º... it will help something if i need to take them out some day...

Still about studs, i dont know how you guys do, but to take the original studs i use 2 nuts against each other... like you can see on photo, with those galvanized studs we can use unbrako keys. Is very mutck easy to use them.

About nuts, my original 9000 nuts are made in stainless steel...
I cant use them twice, or they will not last long (they get out)... Here in Portugal, when i buy new nuts, i use to ask for "Exhaust Nuts". They have a protection made on metal that dont let them get out, so they stay fixed... they cant be used twice because that "protection" will be damage and some day they will get out...

Sorry for my english, i have some problems with technical translations

I will try to get better photos from galvanized studs, termic copper past and nuts then i post here

Regards

McVities wrote:found this example of a jig for drilling out a broken stud or the head ready to accept a heli-coil..............bit OTT but looks good

Now why didn't i think of that!!?

This could solve the problem of drilling my broken stud on my 900 carlsson!

I already have the jigs that people have been using on their 9000's but the 900 turbo manifold is different and will not accept them.If i copy the arrangement in the picture to accept the drilling jig it should work.I could use the removed exhaust manifold as a template for the holes and i guess if made symmetrically could be reversed to drill any hole where there is a broken stud???

Thanks for posting this - i now have a plan

All you need to do is build weld up with a MIG set until you can get grips on the built up weld by which time the heat will have made the broken stud loose.

Will be doing this in the next few weeks, does anyone have the guides available for me to buy/borrow?

Local place wants £60+vat to make up two drill guides! Pffft


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