mef

I am trying to remove 2 studs from my TD05 turbo that were sheared off before I bought it. I've tried to drill them but they are so hard I'm just polishing the surface (using special drills bought from a show that are supposed to drill anything!) Will Titanium tipped drills work better? I've heard of "spark erosion", will I have to get this done or can any one suggest another method?

Thanks,

Martin

timmyjmy93wrx

i had this problem with one of mine.
My mate heated it up with gas till glowing red then got a big chisel on the side of hit and belted it round with a hammer. it soon started to turn

Dont blame me though if it doesnt work for you!!!! dont ho;d me responsible if you damage any other bits of the car!!!!
He's a mechanic and that was the last sraw before the angle grinder came out!!!!

mef

Trouble is they are sheared off flush or even below the face of the turbo flange so theres not much there to chisel at!

timmyjmy93wrx

oh........er........
tough one.....
thats just made it into a right b*ll ache of a job
Cant think of anything else at the moment.
Perhaps someone you has had this prob may be able to tell you how they got round it.

timmyjmy93wrx

Right.
me and me mates think that you were on the right lines of drilling into the centre of the bolts then puttind another bolt/screw into it to use to turn it and going from there. the other way is to do the same but aclualy get a larger size than the current bolt and make it a larger hole for 2 new bolts.
hope this helps and gud luck

mef

OK, thanks for the ideas, I am getting a set of "Cobalt tipped drills" tonight so hopoefully they will be hard enough to make an impression on the studs (well more than an impression I hope, I want a hole!), will let you know how I get on.

Katana

Contact Rally Colin at colin_minton@hotmail.com. He removed mine for cheap.

timmyjmy93wrx

no probs, the cobalt will be good.
make a punch mark where you going drill first it will help loads ( you probably knew just checking!)

scoootie5

You can drill through I have done it before on same turbo, I got my mate to bring his cobolt tipped drills and it went through but it did take a little while and the drill bit was knackered afterwards.

Good luck
Scott

mef

Thanks Scott, well I'm a little more hopeful then now! Will taclkle this job tonight,

Thanks,

Martin

mef

Managed to drill through with the Cobalt drills and recover one thread but the second one is now u/s, the tap got stuck and the thread has gone well oversize now. Looks like I'm lucky in that it can be replaced with a bolt and nut instead of the stud. The only alternative would be a helicoil insert but I dont have any suitable for M10x1.25, dont even know if they are available in that thread.

davedipster

You certainly can get these inserts, have them at work.

Dipster