Finally got round to installing the exhaust on the 911. Gf was getting tired of all the boxes sitting in the corner of the living room.
Old
Lots of heat with a map torch and various penetrants given the 37 year old exhaust studs are highly susceptible to snapping off. Was 11 for 12 studs non-breakage...
But this snapped. That's ok, an inch of stud remaining. Threw the extractor on, then it snapped clean flush. Fack
No worries. Managed to borrow the very expensive exhaust stud drilling jig from a local aircooled guy that (mostly) prevents you from drilling into the head itself which is $$$ and not recommended
But after 3 days of lying on my back, many different size and profile drill bits, and using various upside down drill press renditions, barely a dent made in the stud. None of the bits grabbed the stud and cut further. All spun on the initial dimple like a bearing and did absolutely nothing. As a last ditch effort before towing the car to a pro, picked up these masonry bits
Took multiple renditions of removing jig, cut a bit with masonry bit, installing jig back, using normal 3/16 pilot drill bit, upsizing to bigger 17/64 bit till it stops cutting further, remove jig, cut deeper freehand with masonry bit etc it was done. New studs all in. The brown is a very liberal use of anti-seize. Struggled for over an hour with holding these gaskets in place when I did the job on my old 911 6 years ago. A bit of crafting wire and it took all of 10 seconds to throw these on this time round. #wisdom
And the job that should've taken a weekend that ended up taking 2 weeks is now done. Few more things to button up and then we get to hear how it sounds finally
