I've read all the answers about how to get broken exhaust studs out, but the 2 that I've got are both broken right where they go into the head, so no chance of getting a nut welded on or similar. People have mentioned drilling them out, which I've tried, but I don't seem to be getting very far - what type of drill bit is best for this? I've just read on another site that solid carbide is probably the way forward, anybody agree? and if so, what's the best size to get?

just get some drill bits that you can use on metal - the size really depends on the size of the hole - you basically want to be able to drill the centre of the broken stud so you can get a torx bit hammered in the and then use socket wrench to get it out.

Just to warn you this does not always work 100% - and make sure you drill dead center as not to ruin the existing thread

hope this helps

To save yourself the pain i would take it to a pro who knows what he's doing. I guess its the front cylinders that one of the threads has sheared off You have to be very precise with your drilling. However you may be a braver man than me so good look

Yeah - it's the front nearside ones - I have got the engine out at the moment, so I think a trip to the mender might be the best idea - hopefully they can do it without taking the head off! Anybody got any idea how much it might cost?

I had a similar problem on my car, snapped off just inside the head. I brought a set of stud extractors from e-bay for about £4, you have to drill a pilot hole then screw in the stud extractor which is essentially a very coarse reverse thread. The extractor eventually bites into the snapped stud, you keep turning and hey presto the stud comes out.

be carefull with the drilling and stud extractor,if you snap either one your in deep shit!!!!!

I second that. Best get it done properly first time instead of making it worse. Shouldn't cost too much just shop around. It will be loads cheaper and easier with your engine removed.

i work for an engineering firm, and im sure it wuld not take more than 2 to 3 hrs to get out, think most places charge around £35 an hour. hope that helps.

they should need to take the head off, if need be they could just block the engine up on a mill and drill it out that way

cheers dave