How to remove broken, rusted studs (with a full machine shop)

With summer just around the corner, you should probably start putting the final pieces on your winter project. For some, that could mean finally getting the broken studs out of those rare dual exhaust manifolds that you bought at a swap meet years ago but are finally getting ready to use as intended. You might have tried heating the broken studs and working them with your handy locking pliers … before calling your friend with a machine shop. 

That’s why machinist Adam Booth — better known by his popular YouTube channel Abom79 — is holding the exhaust manifold for a 1964 Oldsmobile. The plan for Booth is simple: Remove the broken studs and remove the factory heat riser from the exhaust manifold. Before removing the studs, Booth uses a die grinder with a carbide burr to extract the shaft and butterfly from the manifold.

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