Quote:
Originally Posted by jcslocum
Be very careful with the easy out. They are brittle like candy canes and very, very hard. If you break it off in there it will NOT drill out. Heat is your friend here, I will disagree with Ben above (he makes a great shifter!!) about the heating. Heat the surrounding head area to grow the hole larger not the bolt. Propane might not be hot enough but it is worth the try. Propane isn't hot enough to harm aluminum so heat for 2 min and try to loosen. Then addd 2 more min. Then let it cool down and start again. Do not heat with the easy out in there.
What size have you drilled it out to???
Do you have all of the other studs out already???
Stomski makes this kit for exactly this job:
https://www.stomskiracing.com/products/boxster-996-997-exhaust-bolt-repair-kit
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Please heed his advice. Take the easy out now and throw it away. It will break off and you will not get it out. I learned that lesson with a moto. I broke off an easy out in the motor case. It cost me $750 to have a machine shop use a laser to vaporise the easy out.
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Current car
2000 Boxster 2.7l red/black
Previous cars
1973 Opel Manta
1969(?) Fiat 850 Convertible
1979 Lancia Beta Coupe
1981 Alfa Romeo GTV 6
1985 Alfa Romeo Graduate
1985 Porsche 944
1989 Porsche 944
1981 Triumph TR7
1989 (?) Alfa Romeo Milano
1993 Saab 9000
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