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[tunnie]

Any tips? All 4 sheared, leaving a sizeable chuck of bolt left in.

Planing to hacksaw off the ends, then drill them out.

Anything I can do to make job easier? Any special drill bits worth investment or just burn through a million el-cheapo ones?

[albitz]

Pita to do while on the car imo. I think its easier to remove the cats to do the job.I was given advice on which type of drill bits to use, but I cant remember the name now.
Dont run the drill at high speed and dont use too much pressure,you will burn the bits out and get nowhere fast. Run the drill quite slow and let it find its own way.
If you have access to thread taps its best to drill them out slightly smaller than the diameter of the studs and then clean the thread out with a tap, allowing you to use new studs/bolts in the original thread. Much m ore professional looking job than nuts and bolts, if you can do it that way imo.

[tunnie]

Cheers, not got any taps, you should know I never have the right tools!

Previous exhausts have been nut and bolted as there was no thread.

Access underneath is actually ok for me, think taking cats off will be more of a hassle....

Think i'll use my Matika drill to attack it, but as you say slowly does it, slowly making my way up in drill bit sizes.

Take it its not a good idea to start with big drill bit?

[albitz]

probably easier to drill amaller pilot hole first imo.

[Elite Pete]

Start off with a small drill bit and work up

[zirk]

I would get some Taps Tunnie, they great tools and if you look after them they will serve you a life time, with Taps your need some cutting paste or theres some good spray can equivalents, use this stuff for the drilling as well, and as Albs says not too fast, if you do use Taps make sure you get the right size final drill bit size as it wont be in your standard box.

Cheap drill bits are false economy in my book, get some decent bits, buy them as you need them, worse case if you blunt them theres still plenty of workshops out there that can re sharpen them for pennies.

Chris.

[tunnie]

Start off with a small drill bit and work up

Did that last time on fatty admins MV6, but you get in even more trouble after you snap those too   

[tunnie]

Guess this should get job done! 

http://www.screwfix.com/p/combination-drill-bit-kit-160-piece-set/88149

[cem_devecioglu]

in summer time when the miggy had the heads re-built, there was some cars having this problem.. I saw a man who welds some pieces and then took them out

[albitz]

Also, dont hacksaw the stumps off, depending on length you may find that when youve drilled to almost the diameter of the studs, you might be able to grip tham with molegrips and undo whats left of the studs, thereby preserving the threads.

[Kevin Wood]

Guess this should get job done! 

http://www.screwfix.com/p/combination-drill-bit-kit-160-piece-set/88149

Not ideal, IMHO. You won't need the masonry or wood drill bits and the steel ones are only noname HSS bits.

I would get a smaller set of cobalt HSS bits - unless you want the other bits?  You will probably get through a few of the HSS bits though.

[albitz]

Guess this should get job done! 

http://www.screwfix.com/p/combination-drill-bit-kit-160-piece-set/88149

Not ideal, IMHO. You won't need the masonry or wood drill bits and the steel ones are only noname HSS bits.

I would get a smaller set of cobalt HSS bits - unless you want the other bits?  You will probably get through a few of the HSS bits though.

Thats the name I was trying to remember.

[tunnie]

in summer time when the miggy had the heads re-built, there was some cars having this problem.. I saw a man who welds some pieces and then took them out

Hummm thats an idea, there is enough left to weld something on, maybe 4" bar or something, that would work when cats were off the car.

Maybe sometime a lot smaller could be welded on, to get some grip on it. Trouble is, would the weld hold any more than the stud?

[tunnie]

Guess this should get job done! 

http://www.screwfix.com/p/combination-drill-bit-kit-160-piece-set/88149

Not ideal, IMHO. You won't need the masonry or wood drill bits and the steel ones are only noname HSS bits.

I would get a smaller set of cobalt HSS bits - unless you want the other bits?  You will probably get through a few of the HSS bits though.

Thats the name I was trying to remember.

Something like this?

http://www.screwfix.com/p/erbauer-hss-cobalt-drill-bit-set-15pcs/95497

[Kevin Wood]

in summer time when the miggy had the heads re-built, there was some cars having this problem.. I saw a man who welds some pieces and then took them out

Hummm thats an idea, there is enough left to weld something on, maybe 4" bar or something, that would work when cats were off the car.

Maybe sometime a lot smaller could be welded on, to get some grip on it. Trouble is, would the weld hold any more than the stud?

Find a nut that will slip over the stud and then weld it on. Give it a good soak in plus gas and have another go. The heat generated when welding will help unsieze the thread.