Stomski jig required, only 5 bolt snapped off today

I had an excellent adventure today. I removed both manifolds from my new low mileage 3.6 engine and only snapped off 5 bolts! I need to Buy, Borrow, rent a Stomski Jig. Does anyone living near Enfield have one i could use? The secret of my success is to use oxy acetelyn. It worked a treat on the R/H manifold but the left hand side just did not want to budge. I will do a write up and post some pictures. Oh i forgot to say it is a 2004 996 engine.

I need to push on so i have bought one. Lets see how i get on :?:

I bought mine with the intention of lending it our for just these occasions. I just need to get it back. MC

I've done 3 of 4 snapped. Just awaiting delivery of some 160mm 3/16 drills (long 17/64ths have already arrived) so I can do the one by the thermostat housing without draining the coolant. One end bolt (on RHS) I used the nearest two fixings which were adjacent to each other. I found this allowed more movement on the jig and I drilled it off centre which made removal of the thread remnants more difficult. I'd recommend adding a third attachment bolt / big washer or use diagonally opposite jig fixings. WD40 was a better cutting lubricant than GT85. Good luck - just go steady, one at a time. This was my best one...(other than the 8 that came out!)

I will bear that in mind. What is annoying, other than the bolts snapping even when heated to a bright red glow, was that afterwards when reverting to the tried and tested method of welding a bolt to the broken one it still would not work loose. I am toying with the idea of fitting stainless steel studs, not that i will ever remove the manifold again, but because that is the way i have always seen manifolds fastened to an engine. Obviously old cast iron engines that is. Any idea of the ideal stud size?

I have one of the PPBB Ti stud kits I bought ages ago. The studs are threaded each end with a plain bit in the middle. 15mm thread, 11mm plain then 20mm threaded. 46mm total. They are M8 x 1.25 threads

I could do with borrowing the 911 (964) version of this if someone has it. I only have one stud resisting, so buying it seems a bit excessive. (I also put the ppbb titanium studs on my 997)

I always ask for a deposit when I rent mine for this reason as PPBB told me he lots 3 sets because people didn't return them

Thanks for the info on the stud size. I have been trying to find something similar in stainless steel but no luck as yet. If i cannot find them then i will just use self locking flange head setscrews and have done with it.

Before you get the drill out, I really recommend these laser stud extractors. As long as there is a bit of the snapped stud protruding they work a treat. Stupidly when I changed my manifolds, I cut all of my snapped studs down in preparation for drilling but then I found these. All the studs that still had a bit poking out, this tool removed them. They work best with an impact gun https://www.halfords.com/tools/power-tools-and-accessories/power-tool-accessories/stud-extractor-set---1-6mm%2F6-12mm-2pc-208318.html?istCompanyId=b8708c57-7a02-4cf6-b2c0-dc36b54a327e&istFeedId=367c5610-f937-4c81-8609-f84582324cd6&istItemId=ittamtrxi&istBid=t&_$ja=tsid:| For stainless studs, I used these. They don't have flat sections so a bit more fiddly, but they come with aerotight nuts and washers https://www.ebay.co.uk/itm/390926353150

Believe me if getting the bolts to almost melting using an oxy acetelyn torch will not shift them, and even welding nuts to the broken studs did not work then i have no doubt whatsoever that the laser tool would also fail. In any case the jig arrived this morning and 4 of the 5 snappers have been drilled out. What 'they' don't make crystal clear is that on the left hand bank (cyl 1.2.3), the first bolt from the back of the engine is obscured by the thermostst housing, which i only fitted on saturday morning, and the 2nd bolt along is in such a position that you need a very long drill bit to get your drill near enough to drill the bolt out. Dont' believe the video, everything is easy with a bare head and a new bolt on a bench! Ha!!

Just awaiting the long 3/16 arrival from ebay to check and I'll send you the details. The long 17/64 arrived already.I didn't fancy dropping the coolant!

I'm about to start removing my manifolds this weekend. I've got various tricks up my sleeve but I'm sure that a few bolts won't come out and will need drilling. To those that have just bought Stomski jigs and have completed the work can I rent/buy your jig? I'm thinking that as you've completed the job the jig maybe surplus to requirements? PM me if interested. Thanks

Aha!, where did you get the long drills from, i cannot find any locally or on ebay. And KERSIDAN i might consider renting/selling my jig when the job is done. Depends on how quickly you need it.

I'll be in touch re drills once 3/16 arrive. I'll get the jig on and double check they'll work and enough length to fully drill the stud.