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Originally Posted by insite
okay, update time! let's dive right in. when last i posted, i had an issue with some broken head studs. let's start there. these things were completely welded in place; no way to extract other than to drill.
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this obviously took awhile. FYI, helicoils are awesome. they come in 1/2" deep inserts, but you can stack two, which is what i did in this case.
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Insite:
Really, really excellent photos!
I went through something similar when installing headers in place of the stock exhaust manifold on a 10 year old Boxster. 4 of the 6 exhaust manifold bolts on the passenger side sheared off, the rest of them came out in one piece. I was able to drill in the center of each bolt until there were just threads left, at which point I was able to back some of them out and tap out the others.
Have you thought about installing studs onto the cylinder heads, instead of using bolts? After less than a year, the factory bolts that I used to install the new headers on my Boxster are already rusting, so I have sourced coated studs, phosphor bronze lock washers and brass nuts. I plan to replace the bolts with studs in the spring.
Thanks for taking the time to document your project so thoroughly!
Regards, Maurice.