pyropete125

Hi all,

With a bit of luck I am picking up a 86 944 Turbo tomorrow evening. I think I am going to be getting a good deal on it, nice shape body, just faded paint, turbo brakes, aftermarket cobra seats, LSD... only major problem is is broken below the block surface from the pictures the owner sent me. The current owner popped the head gasket and while disassembling he snapped the drivers side second stud from the back.

My plan is to use my magnetic drill that I can chuck up an endmill in, after a make a 1/2" plate that I can bolt to the block surface to have the drill stick to. I have a drill chuck that I can use for some cobalt or carbide drills in. Is this a good way to approach this? Any other tips or tricks?

While the head is off I am going to do a good multi-angle valve job and check for flat. Anything else that I should do? Should I use any particular brand head gasket for replacement?

Thanks all in advance,
Pete

tempest411

That sounds like a good plan if you are lucky enough to have the resources to do that. I would plan on finding a way to heat up the block when you are able to get an easy-out type remover down in there, however. They used the red high-strength thread locking compound on the head studs from what I understand.

odonnell

Is taking it to a machine shop an option? They could probably sort it out. There's also a guy on here (333pg333 I think his username is) who had his block time-serted on purpose for thread strength, so surely worst case scenario, drilling + thread repair is an option.

pyropete125

Well I did get the car. Its is my first turbo 944. the stud broke right at the first thread exposed from down inside the stud hole.

Maybe one night this week I will have time to start working on it.

Thanks,
Pete

944crazy

What about welding a nut to it...that way you don't risk ruing the thread by drilling into it. If it doesn't work and the weld breaks, you can re-weld and try again, or try to drill it out.

pyropete125

It's an inch or so below the surface of the block. It's the missing stud in the picture

V2Rocket

Search your local area for "EDM" services...
It'll be $100-$200 but the repair will be perfect and clean.