wastegate studs are broken will they come out

Guest · Jul 12, 2006

took the wastegate off its a 911 turbo 2 and all the studs were rusted and have broken off can these be removed if so how and how much should it cost as if its going to be expensive i may as well try for a tial wastegate but cant find a uk supplier

Nick Moss · Jul 12, 2006

I have just replaced the entire exhaust system on my 3.3 myself. Almost every stud and bolt had to be cut, ground or chiselled off, even the ones in the head. I tried to get the ones in the head spark eroded but because they are high tensile this process wasn't successful so the were drilled then Timecerted. I suspect this is what you will need to do, and of course will probably require the pipe to be removed. Be careful not do damage the front-to-rear exhaust pipe, they are over £1200 from Porsche!

Guest · Jul 13, 2006

i presume the front to rear pipe is not part of the wastegate i have aftermarket headers would i still have this pipe you are referring to

Nick Moss · Jul 13, 2006

I would guess that even with aftermarket headers (I have Dansk heat exchangers and a Watson crossover pipe) you will have the Porsche front to rear pipe. The studs are in the wastegate not the pipe. My warning was to make sure you don't damage the pipe when getting the wastegate off, although you have obviously already achieved this.

nathan 1981 930 G50 · Jul 16, 2006

911 2, I don't think you will have that pipe from what I remember about your car.

Nick, I had heard about EDM for removal of studs and presumed that it worked. I renewed my exchangers with GHL's on my 930 recently and the only thing that was a problem was the wastegate so I bought a Tial 46 from the USA. I drilled one out to prove that I could do it but I got bored very quickly and I was also slightly off centre...

I think 2 of the allen type nuts snapped off the studs but my new exchangers flanges were not so thick so I just ran a die up the studs. The studs that I did get out I replaced with Stainless steel.

Did you use SS studs to replace them ? or are you selling the car anyway ?

Nick Moss · Jul 16, 2006

I haven't replaced the wastegate studs yet, the front to rear pipe is still at my OPC awaiting collection, and I will do the studs then. I have aleady bought genuine part studs which I think are high tensile rather than stainless. I have already replaced all the head studs with genuine parts.

nathan 1981 930 G50 · Jul 16, 2006

It's nice to keep a car genuine. My 3.2 only has minor mods like the turbo tie rods, K&N air filter. I have my doubts about the K&N sometimes.

My theory with the SS studs & nuts is that if they do not corrode I should never need to remove them.