dan1066

1982 5 speed.

I have the engine out of the car for a variety of repairs. I was attempting to drill out a broken exhaust header stud, the rear most one on the passenger side (broken below flush) and I drilled through the stud and into the cooling jacket.

Once the stud is finally out, can the entire hole be plug welded and re-tapped or did i just end up buying a new head?

Thanks

Speedtoys

I would say that could be plug welded/etc.

Coolant passage isnt exactly high pressure on the repair.

17prospective buyer

Don't see why not... after all, welding heads for cracks and stuff is common and resilient if it's done properly. I would think you should bring it to a place that can weld it properly so no warping goes on.

Roy928tt

I wouldn't even bother welding up the hole, a little sealant on the stud when you fit it and you'll be right.

Detroit Diesels have exactly that configuration, the exhaust manifold stud holes go through into the water jacket !

Cheers Roy

FBIII

+1
A lot of bolts seal in the water jacket.

ZEUS+

Many Chrysler V8's have been that way for along time also. Jb weld on stud threads and in head works best.

namasgt

Buying a used cylinder head should not be too expensive if not almost for free....

dan1066

I appreciate all the feedback. I apologize for not getting back sooner but this work thing has a nasty way of distracting me from my 928. Since I've got to pull the head to get the last two broken studs off, I'm going to investigate plug welding and tapping a new hole. I will keep you posted.

The Fixer

Be better not to weld imo, could make things worse.

Sealing will work fine, may bother you a little, but with work fine.

The case sealant: Permatex FORM A GASKET SEALANT would do the trick.

Speedtoys

Ya..the feedback says "dont weld". Heat can be very bad for you.

Stud & Seal it.

The Fixer

Dan, come to think of it, for threads Locktite 545 will do the trick.

agree, i too was always told not to heat an aluminum head in a specific area.