No. 65 Exhaust Stud Drill Jig
SKU: No. 65
$149.95Price
Our Exhaust Stud Drill Jig makes easy work of drilling out a broken exhaust stud. Sometimes welding the stud will help you get it out, but there are times when welding just doesn't cut it. When the head is on the motor and you're trying to get in there, it can be a real challenge. If the motor is still in the frame, it's even worse. Or if the stud is broken off like 1/4" down inside the hole, then forget about it. Our drill jig is a lifesaver in these times.
Product Info
- 6061-T6 aluminum with Cerakote finish
- Includes 1/4" drill bit
- Fits all Evo Big Twin, Evo Sportster, and Twin Cam models. In most applications, it can even be used while the engine is still in the frame.
- 100% made in USA
How to use
- Note: You need straight-on access to the broken stud in order to use this drill jig. In some instances, this may not be possible and you must either remove the cylinder head, or pull the engine from the frame.
- Install drill jig with drill bushing over the broken stud. Broken stud must be flush with, or be below the surface. You want to be able to fasten the jig down all the way to ensure you're drilling straight down the stud.
- Install the 1/4" drill bit in your drill and start the hole by just pecking at it at first, to be sure you're drilling straight. A center punch can first be used, if available. Although the drill bushing does a pretty good job at making sure the bit doesn't wander off center.
- Use cutting oil and frequently pull drill out drill bit to remove the chips. Do this at least every 1/4" of drill depth. You want to drill out the entire stud. Most exhaust studs are threaded in from .750 to .820 deep. You should feel the end of the stud, but if you're worried about it, you can put a piece of tape approximately 1.50" above the tip of the drill bit, which would give you the correct approximate depth once the tape starts touching the drill jig.
- Using tapping oil, run a 5/16-18 tap down the hole. Go slow and start with medium pressure. In most instances you'll get lucky and the tap will travel down the original path of the threads. In some instances, the threads will be damaged and the hole will have to be repaired with a Time Sert or Helicoil a new stud can be installed.
- See video above for more details