Just removed the turbo

[lloydy]

And some a*** welded the studs on the turbo to exhaust maniflold, obviously couldn't find four nuts
Now gotta hope the recon place can extract the studs as i had to grind them off, and my stud extractor kept snapping the studs

[spannermonkey]

lloydy,

This had happened with my 16, the downpipe from turbo to muffler had been previously repaired and exactly that - mig weld over the studs!

As necessity to get it on the road I replaced the downpipe and 3 studs but could not remove the fourth; it's been fine for 18 months or so and never blows, but is on that mental list of jobs to do!(Unless of course I replace the engine first )

Steph

[lloydy]

mines off, really hoping the turbo place can get the studs out, otherwise it's big money for a new turbo. What makes people weld over studs

[syncropaddy]

I had the same issues as well but I was replacing my turbo with a new one. The only way I found to remove the broken studs was to mount the turbo in a milling machine and carefully mill them out and follow up with a tap to restore the threads in the turbo flange.

Ian ..... there is an idea for you !!

[lloydy]

Ian ..... there is an idea for you !!

Hmm might have to call on ian if they can't get them out.
Hopefully all will be sorted by midland turbo, don't want it off the road for to long. It's the only thing stopping me driving it now, esp as i've got MOT and tax done

[Essex Nige]

I'm sure they can, i took mine to a local engineering/engine rebuild place and they removed all snapped bolts and studs

[HarryMann]

muffler

Steph, sorry we don't know what of them is here...

As for welded 'studs', a photo might show exactly where and therefore why welded up... very strange business!

JX manifold/turbo bolts £13/each

[lloydy]

muffler

Steph, sorry we don't know what of them is here...

As for welded 'studs', a photo might show exactly where and therefore why welded up... very strange business!

JX manifold/turbo bolts £13/each

Sorry no pics, as it's all boxed up now. It wasn't those bolts, they came out quite easy. It was between the turbo and downpipe
this flange

[HarryMann]

Ohhhhhhhhh, thaaat one

Nio, can't see why welding thems would be necessary

[silverbullet]

I had the same issues as well but I was replacing my turbo with a new one. The only way I found to remove the broken studs was to mount the turbo in a milling machine and carefully mill them out and follow up with a tap to restore the threads in the turbo flange.

Ian ..... there is an idea for you !!

I hate doing turbo studs.
They are really, really tough special stainless (to withstand the duty cycle at high temps) or should be if some berk hasn't replaced them with m/s rubbish, welded them or "had a go" at drilling them out themselves

[lloydy]

so you won't be happy if i pm you wednesday begging you to drill out my studs, (you'll get an extra choccy biccie on saturday)
I'm sure turbo place will do it anyway

[syncropaddy]

I had the same issues as well but I was replacing my turbo with a new one. The only way I found to remove the broken studs was to mount the turbo in a milling machine and carefully mill them out and follow up with a tap to restore the threads in the turbo flange.

Ian ..... there is an idea for you !!

I hate doing turbo studs.
They are really, really tough special stainless (to withstand the duty cycle at high temps) or should be if some berk hasn't replaced them with m/s rubbish, welded them or "had a go" at drilling them out themselves

Pop it up on a Bridgeport ...... and use a good TiCN cobalt 3 flute slot drill. Worked for me!

[silverbullet]

It's a "just" job...done enough to know they're always ruddy hard work. People get all exciteable when you've spent all morning sweating your eyebrows off, "just" to remove a handful of studs and leave them with (perfect, mind you) threaded holes for new bolts or studs.

[syncropaddy]

It's a "just" job...done enough to know they're always ruddy hard work. People get all exciteable when you've spent all morning sweating your eyebrows off, "just" to remove a handful of studs and leave them with (perfect, mind you) threaded holes for new bolts or studs.

I know. It took me almost an hour just to set it up and plot the x/y. Then of course the first slot drill broke!