Modern Vespa : Sheared Exhaust stud-GTS

Sheared Exhaust stud-GTS

OP starreem UTC details Ossessionato 07 GTS250(RIP), 07 LX150, Several Lambrettas Joined: UTC Posts: 2834 Location: Raleigh, NC
OP starreem Ossessionato 07 GTS250(RIP), 07 LX150, Several Lambrettas Joined: UTC Posts: 2834 Location: Raleigh, NC	UTC quote Anyone had any success removing a stud sheared flush with the exhaust manifold *without* removing the engine?

cheekythomas UTC details Molto Verboso Joined: UTC Posts: 1044
cheekythomas Molto Verboso Joined: UTC Posts: 1044	UTC quote Yes plenty.. but requires a mig welder!

OP starreem UTC details Ossessionato 07 GTS250(RIP), 07 LX150, Several Lambrettas Joined: UTC Posts: 2834 Location: Raleigh, NC
OP starreem Ossessionato 07 GTS250(RIP), 07 LX150, Several Lambrettas Joined: UTC Posts: 2834 Location: Raleigh, NC	UTC quote Educate me. There's nothing sticking out from the engine. It's flush. ⚠️ Last edited by starreem on UTC; edited 1 time

jess UTC details Petty Tyrant 0:7 and counting Joined: UTC Posts: 38658 Location: Bay Area, California
jess Petty Tyrant 0:7 and counting Joined: UTC Posts: 38658 Location: Bay Area, California	UTC quote Ditto. You can build up a tip of weld even if the ~~bolt~~ stud is sheared below the surface, and then weld a nut to the built-up tip. Welding in that tight spot is a giant pain, though. For me, it meant welding without a mask, closing my eyes, and letting the weld spatter hit me in the face. ⚠️ Last edited by jess on UTC; edited 1 time

Paul G.

UTC

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GTS 250ie

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Location: Rhode Island

Paul G.

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GTS 250ie

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Posts: 2047
Location: Rhode Island

UTC quote

Jess had success, but his stud was protruding some.

Flush with the head probably means removing the engine.

Because of the location of the pivot, you can't get a straight shot into the right stud with a drill and easy out.

The left stud is theoretically possible, but if you slip off of the hard steel stud remnant, you will absolutely damage the soft aluminum head. That would force engine removal and machine shop work.

Sorry, it sucks.

P.

starreem

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Ossessionato

07 GTS250(RIP), 07 LX150, Several Lambrettas

Joined: UTC
Posts: 2834
Location: Raleigh, NC

starreem

Ossessionato

07 GTS250(RIP), 07 LX150, Several Lambrettas

Joined: UTC
Posts: 2834
Location: Raleigh, NC

UTC quote

It's the left stud. I have a mig welder, but my skilz are laughable.

I'm off an a long journey tomorrow, and I think my best option is to find a way to wire up the header/collar to keep the vibration down as much as possible. The right nut is loose, but it won't come off due to corrosion on the exposed threads. I'm thinking if I try and snug up the remaining nut, the added lopsided pressure will surely shear the right stud.

jess

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Petty Tyrant

0:7 and counting

Joined: UTC
Posts: 38658
Location: Bay Area, California

jess

Petty Tyrant

0:7 and counting

Joined: UTC
Posts: 38658
Location: Bay Area, California

UTC quote

starreem wrote:

It's the left stud. I have a mig welder, but my skilz are laughable.

Yeah, mine too. Took me all day to get that nut welded on right, and I had the benefit of having some of the stud sticking out.

starreem wrote:

I'm off an a long journey tomorrow, and I think my best option is to find a way to wire up the header/collar to keep the vibration down as much as possible. The right nut is loose, but it won't come off due to corrosion on the exposed threads. I'm thinking if I try and snug up the remaining nut, the added lopsided pressure will surely shear the right stud.

FWIW, I've ridden around for over a month with one broken stud, with no ill effect. I wouldn't think vibration would be too much of a problem if the rest of the exhaust is properly bolted down.

Harvey UTC details Ossessionato 2016 Honda NC750XD, 2007 GTS (sold), Joined: UTC Posts: 3517 Location: Canada
Harvey Ossessionato 2016 Honda NC750XD, 2007 GTS (sold), Joined: UTC Posts: 3517 Location: Canada	UTC quote This thread suggests that it should take about 2 hours for a really good shop to repair. Really long repair time Harvey

OP starreem UTC details Ossessionato 07 GTS250(RIP), 07 LX150, Several Lambrettas Joined: UTC Posts: 2834 Location: Raleigh, NC
OP starreem Ossessionato 07 GTS250(RIP), 07 LX150, Several Lambrettas Joined: UTC Posts: 2834 Location: Raleigh, NC	UTC quote Thanks for the advice, Hell, for all I know I've been driving around since February like this. That's the last time I had the rear wheel off. I've not noticed any change in sound from the exhaust either. I'll keep my fingers crossed for my adventure and deal with the mess when I return. I'm due for coolant change, and brake fluid change anyway-good time to learn to pull the engine...

Harvey

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2016 Honda NC750XD, 2007 GTS (sold),

Joined: UTC
Posts: 3517
Location: Canada

Harvey

Ossessionato

2016 Honda NC750XD, 2007 GTS (sold),

Joined: UTC
Posts: 3517
Location: Canada

UTC quote

I bumped into this post on another forum:

goodfellow;151620 wrote:

What's the diameter of the bolt? and do you have enough room to get an arc welding rod in the hole

If it's large enough to fit a steel sleeve down the hole to touch the broken mess you now have, then it may be a bit easier than your stud removers (I never trust those things anyway)

On a good welding surface I would weld a nut to the top of the sleeve to get good penetration. Then insert the sleeve down the hole - insert an appropriate size welding rod (I use 6013) down into the sleeve while holding everything steady.

Then have a buddy turn on the welding machine and weld the sleeve to the broken part and backfill the sleeve with metal as far as possible.

The heat will loosen what's already in there and you have a good solid nut on top to apply torque.

A buddy of mine used this technique, but since he didn't have a sleeve, he used a a cheap bolt that he drilled out lengthwise so he could get his electrode down to the broken stud. It's a bit more work, but he eventually got his 4 broken studs out.

From http://www.garagejournal.com/forum/showthread.php?t=13431

Hopefully it will be helpful.

Harvey

ks7877 UTC details Ossessionato Joined: UTC Posts: 2342 Location: So Cal
ks7877 Ossessionato Joined: UTC Posts: 2342 Location: So Cal	UTC quote I had the same problem, Starr. It was discovered and repaired by Jeff at Motorsports after I got back from Tennessee last summer. (By the way, he said I could have ridden around a while longer, as is, without much worry.) Maybe give him a call when you get back. starreem wrote: . . . I'm off an a long journey tomorrow . . . Where ya goin? Holler if you end up near So Cal.

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