Exhaust Stud Removal Drill Guide Tool

R1200GS LC, R1200GSA LC, R1200 GS LC, R1200 GSA, R1200GS Adventure, R1250GS, R1250GS Adventure,  exhaust header stud removal tool, broken exhaust stud removal tool

We recently had to remove a broken stud from a 1200LC engine (it snapped whilst removing the headers). It`s a pig of a job, if anyone has had to do it before, however during the process we came up with a handy little tool which ensured that the initial pilot hole was as central as possible.

Very simply, all it is is a `top hat` design drilling guide machined from black bar (so it isn't the prettiest steel in the world) that sits over the broken stud end with a 3mm hole in the middle. This allows the 3mm drill (suggested pilot drill size) to start in the centre of the stud, allowing following drills to follow this central pilot hole. I`ve personally tried centre punching by hand and its very difficult to get the same accuracy that this little tool gives you.

It`s a two person job with one person holding the tool over the end of the stud and one person operating the drill with all appropriate PPE and safety precautions being taken of course to avoid injury.

The stud removal, in any case, is not for the fainthearted and we would respectfully offer the following `top tips` based on our experience, apologising for any offence caused to far more skilful people than us;

1. Ensure the face to be drilled is flat so not to push the drill off.
2. Ensure that as you drill the drill is kept in line with the stud.
3. Only use top quality new drills.
4. Drill slowly using plenty of drilling oil.

Once a straight pilot hole is drilled you can then open it up to suit the size of your stud removal tool, not forgetting the use of patience, heat and copious amounts of releasing fluid.

If any support is needed for removing a broken stud then please don`t hesitate to call as we are happy to offer phone support to assist. The attached images show the following;

1. The drill guide itself
2. A broken stud (the tool fits over the `stump` of course).
3. Drilling using the tool held in place.
4. A stud consequently drilled out to accept a stud removal tool.