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Old 02-08-2017, 08:10 PM
BobinSF BobinSF is offline
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Unhappy Broken Manifold Studs

While attempting to remove a threaded plug from the top of the exhaust mixing elbow, I felt something give way; I had broken all three of the studs holding the manifold to the block. The looked very rusted.
My path to repair seems to be the following:
1. Remove the manifold, after unbolting the carburetor and disconnecting the water inlet and outlet hoses and the tube from the bottom of the carburetor to the intake manifold.
2. Try to remove the three stud stubs from the block with the stud remover tool.
3. Failing in the above, drill out the stud stubs, tap and place three repair bushings in the block.
4. With new manifold studs and manifold gasket, replace the manifold and reconnect disconnects from #1.
My A4 is very tight in my Tartan 27. If #2 fails, it probably means removing the engine to do #3. All this definitely pushes my skill level, so having the boatyard repower with a Moyer rebuilt A4, or going electric, looks tempting. Any advice would be most appreciated.
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