Porsche 996 , 997 Turbo, GT2, GT3, GT3 RS Exhaust Manifold Stud Drill Jig Kit  
porsche spares made in britain by verboten-motorsport

Porsche 996 , 997 Gen1 Turbo, GT2, GT3, GT3 RS Exhaust Manifold Stud Drill Jig Kit  

£305.00

Porsche 996 , 997 Gen1 Turbo, GT2, GT3, GT3 RS Exhaust Manifold Stud Drill Jig Kit

This Exhaust Head Bolt repair kit for Porsche 996 GT3 ,GT3RS, GT2 and Turbo , 997 Turbo, GT2, GT3, GT3 RS Exhaust Manifold Stud Drill Jig Kit

This  Porsche 996 , 997 Turbo, GT2, GT3, GT3 RS Exhaust Manifold Stud Drill Jig Kit   is a well designed and precision manufactured kit and enables you to remove and re-thread the Exhaust manifold studs without going through the pain of engine removal.

Having carried out a number of manifold removals we have created this kit to overcome the issues that are faced and makes a tricky job well within the ability of motor technicians and motivated DIY mechanics alike.

porsche-parts-exhaust-manifold-titanium -studs-manufactured-by-verboten-motorsport

Availability: 10 in stock

Porsche 996 , 997 Gen1 Turbo, GT2, GT3, GT3 RS Exhaust Manifold Stud Drill Jig Kit

(Not suitable for 996.997 Gen2 ,C2.C4,C4S,986 Boxster,987 Boxster-Cayman)

This well designed kit enables you to remove and re-thread the Exhaust manifold studs without going through the pain of engine removal.

Having carried out a number of manifold removals where the OEM bolts have snapped off we have created this kit to overcome the issues that are faced.

The kit comprises of a precision CNC machined drill jig. Its lightweight but robust to ensure your arms are as less stressed as possible when initially holding it in place.

We supply two Easy Locator threaded collars to either locate on the remains of broken off studs or from the threaded hole that remains after the occassional successful stud removal.

The kit contains a hardened pilot hole drill bush that also locates over the remains of a exhaust stud if required. Used in conjunction with the supplied pilot drill enables a pilot hole to be drilled in the stud remains. The drill bush is held in by the supplied drill bush locking screw.

Once the pilot hole is successfully drilled, the Pilot hole drill bush is replaced with the hardened Core Removal drill bush and again tightened down using the drill bush locking screw.  After checking the correct depth the core of the exhaust stud is drilled out.

The remains of the stud can now be worked out using needle plyers and the supplied engineers pick.

Once the stud remains have been removed and then the thread hole is blown out with compressed air remove the Core removal Drill Bush from the Jig and insert the threading bush To identify this bush it is the one with the largest hole through it and big enough for the tap to fit through. Do however be careful as the thread tap and bush are both made of hardened material and the tap will be damaged by the bush if you use undue force ! . This bush helps to ensure the thread tap is presented to the thread hole true and square. Carefully and slowly insert the tap into the stud hole using our thread tapping lubricant using the tap holder and socket extension on a rachet to clear out the existing thread. Once this is completed again use compressed air to blow out any remaining thread residue.Make sure you are wearing safety glasses or goggles as sods law dictates that the metal particles usually end up in you eye !

Once you are sure the thread  is clean you can move onto inserting your titanium studs. we recomemd using our specially formulated stud lock.This has been formulated especially for air cooler cars and to not breakdown under the operating temperature.. Only use it on the end thaqt is being inserted in the cylinder head. Do not use it on the nut end.

Finally once all bolt remains have been removed go and have a beer or non alcoholic beverage of your choice to celebrate a job well done !

 

 Manufactured by : Verboten-Motorsport.com
Weight2.222 kg
  • 1 x high precision CNC machined Aluminium location Jig.
  • 3 x high precision drill bushes manufactured in Hardened Hard wearing steel.
  •  1 x  high precision tap guide bush manufactured in steel.
  •  1 x standard length high quality European manufactured pilot drill.
  •  1 x long length high quality European manufactured pilot drill.
  •  1 x standard length high quality European manufactured core removal drill.
  •  1 x long length high quality European manufactured core removal drill.
  •  1 x UK manufactured high quality thread tap.
  •  1 x extension tap holder with ratchet feature.
  •  2 x  aluminium locator plugs complete with long and short grub screws.
  • Engineers pick for removal of bolt remains from threaded hole.
  • 2 x Allen Keys suitable for the bolts used in this kit
  • Strong plastic lidded case for convenient storage.

Usage Guide

This Exhaust Head Bolt repair kit for Porsche 996 GT3 ,GT3RS, GT2 and Turbo , 997 Turbo, GT2, GT3, GT3 RS Exhaust Manifold Stud Drill Jig Kit
comprises of a precision CNC machined drill jig.
It’s lightweight but robust to ensure your arms are as less stressed as possible when initially holding it in place.
We supply two Easy Locator threaded collars to either locate on the remains of broken off studs or from the threaded hole that remains after the occasional successful stud removal.
Ensure hole depths are measured prior to drilling and use of drill/tapping lubricant to cool and lubricate the drills.
The Exhaust Head Bolt repair kit for Porsche Boxster / 996 / 997 kit contains a hardened pilot hole drill bush that also locates over the remains of a exhaust stud if required.
Used in conjunction with the supplied pilot drill enables a pilot hole to be drilled in the stud remains. The drill bush is held in by the supplied drill bush locking screw.
Once the pilot hole is successfully drilled, the Pilot hole drill bush is replaced with the hardened Core Removal drill bush and again tightened down using the drill bush locking screw.
After checking the correct depth the core of the exhaust stud is drilled out.
With this Exhaust Head Bolt repair kit for Porsche Boxster / 996 / 997 you are, with care, able to reach the end holes in each exhaust bank to drill out the broken bolts. Frustratingly our competitors repair kit is not designed to accomplish this task. Having carried out this job under the car on many occasions we believe this is a invaluable for completing the job correctly and efficiently.
The remains of the stud can now be worked out using needle plyers and the supplied engineers pick.

Once the stud remains have been removed and then the thread hole is blown out with compressed air remove the Core removal Drill Bush from the Jig and insert the threading bush.
To identify this bush it is the one with the largest hole through it and big enough for the tap to fit through. Do however be careful as the thread tap and bush are both made of hardened material and the tap will be damaged by the bush if you use undue force ! This bush helps to ensure the thread tap is presented to the thread hole true and square. Carefully and slowly insert the tap into the stud hole using thread tapping lubricant using the tap holder and socket extension on a ratchet to clear out the existing thread.
Once this is completed again use compressed air to blow out any remaining thread residue.Make sure you are wearing safety glasses or goggles as sods law dictates that the metal particles usually end up in you eye ! Once you are sure the thread is clean you can move onto inserting your titanium studs.
We recommend using our specially formulated stud lock. This Stud lock has been formulated especially for air cooler cars and to not breakdown under the operating temperature. Only use the Stud Lock on the end of the stud that is being inserted in the cylinder head. Do not use it on the K-nut end.
Finally once all bolt remains have been removed go and have a beer or non alcoholic beverage of your choice to celebrate a job well done !
Other components we suggest you consider : Titanium Exhaust Manifold Studs : More Details Here High Performance Ceramic Anti-Seize Compound. : More Details Here

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