Hi Paul;
Thanks for the photos and the advice. It is appreciated.
Those are the same studs I have Tom. I bought the longer ones because they are longer on the nut end but the same on the manifold end. The extra 1/4” helps when you have to get the flat washer, lock washer, and nut on the invisible (downward pointing) stud in the unreachable spot with one hand while lying in a locker with your head twisted sideways and something digging into your ribs. 
+1 on the thin socket too. There is so little room between the exhaust elbow and the nut that even with a thin socket you may have to wiggle the manifold in the slots on the elbows to get the socket on both sides.
Very satisfying when it all goes back together and works though!
Thanks for the photo and in depth explanation.
I just got back from the boat, and was able to remove three of the bolts with minimal pain and suffering. I couldn’t find any combination of sockets and attachments that were long enough to reach the final bolt and short enough to clear the air intake, so I came home and ordered a deep socket which hopefully will fulfill both dimensional requirements.
Maybe I am reading your post wrong but you seem to be saying that the bolts that attach the manifold to the engine are 5/16. The ones I removed today are 1/2". So far all three have come out complete with stud.
I know you can get the studs from Westerbeke. I ordered 2 of the smaller ones that are used on the front and back plates and was charged a ridiculous $7.12 each. Is there any reason not to reuse the ones that are already there if they are in decent condition? I was figuring I would clean them up and put them back in. I don’t find the prospect of paying $30+ for new ones particularly appealing.
Did you replace all your hoses while you were at it? So far all of the ones I have removed look original. Some of them were so hard and inflexible I had to cut them to get them out of the way.
Thanks again for the helpful photos and advice.
Hope its a deep skinny socket. Then it should work.
That’s right - the nut on a 5/16 diameter bolt takes a 1/2 inch wrench or socket. Yes it’s confusing.
I could not find 1/4-20 studs (two different nut sizes for these) anywhere so I just made my own by sawing up bolts. I almost just used regular bolts on these 10 end bolts but I thought if in the future these had to come out again and they seized in the aluminum I might get the nut off. There was white stuff on the old studs, could have been corrosion or it could have been TeffGell. In any case I won’t have to do it again…
All hoses were replaced a few years ago. These new hoses were still in good shape. Except for the Injection nipple to muffler 2" hose, that was original, I destroyed it to take it off. Unfortunately the new 12" long piece I bought is much heavier and stiffer than the original so it may be a struggle to put on.
Tom
If 18-8 stainless steel studs are acceptable to you, or if you’re willing to cut 12" 316 threaded rods down to length, take a look at:
They’re a good source of materials. I tend to wait and buy enough at a time to justify the minimum shipping cost, but I’ve also bought small quantities because their prices are reasonable and their turnaround’s quick.
– Bob
Solar Wind
Nonsuch 26C #143
This is the stud you need. https://www.amazon.ca/Exhaust-Inlet-Manifold-Studs-Length/dp/B07BH3XLHS?th=1
I got mine at Bumper to Bumper auto parts and I certainly didn’t pay $23!
Paul M
NS30U #211, Sandpiper
Cowichan Bay B.C.
Same item Amazon US $10.99
That’s called “country pricing“. Smaller market, bigger spaces…
Guys: It would be a whole easier to follow your work if nuts, studs, bolts and bolt heads were more precisely identified. They seemed to be mis-identified in several places.
Joe
I seem to keep digging myself deeper into a hole. I picked up a 1/2" deep socket and an assortment of extensions and spent well over 2 hours trying all kinds of different length combinations with no results. I tried three different ratchets and the problem seems to be that the ratchet diameter prevents me from being able to guide the socket assembly vertically up the confined space to engage the nut. At the end of all that I asked myself the question “even if I do get this bolt out, how would I ever hope to get it back in when it is time to reassemble the manifold?”. At that point I decided to hope that the source of my leak wasn’t either of the two elbows at the bottom of the manifold, but somewhere in the end assemblies - which is where I started out believing them to be anyway. I removed the 10 bolts holding on the end assemblies (only breaking off 4 of the studs in the process) and naively tried to peel off the end assemblies. Needless to say; neither of them would budge! Hence my statement about digging myself into an ever deeper hole.
Are the end assemblies glued onto the manifold with some kind of sealant. The parts diagram shows just a gasket placed between the two. How did you manage to separate the parts, and how much force did it take? I grabbed the exhaust elbow and heaved on it until the boat was literally rocking in the cradle but nothing on the engine budged a mm.
My launch date is in one month from today and if I miss it I am done for the year. Time to consider paying a real mechanic to come in and fill in the hole I have dug!
Ralph Bush
1983 N26C #104
“Hyggelig”
EYC, Toronto, ON
You won’t likely be able to remove the broken studs without having the manifold on the bench. Are you sure the socket you have is thin enough to get between the nut and the side of the elbow. If not it won’t matter what extension you use, It is very tight. Can you photograph it with your phone?
I can fit the socket into the space and it engages the nut. I simply can’t come up with any way to attach a ratchet that will work. Also; I don’t see how you could possibly get that bolt replaced at the end of the repair. At least coming out gravity would be working with you.
I can fit the socket into the space and it engages the nut. I simply can’t come up with any way to attach a ratchet that will work. Also; I don’t see how you could possibly get that bolt replaced at the end of the repair. At least coming out gravity would be working with you.
Have you tried a u-joint extension?
Ralph: A couple of suggestions – try using a 1/4” drive ratchet set. Also, obtain 6 point sockets as they will not slip off the nuts as easily as the 12 point ones. In addition, you can get flex-head sockets that may more readily grab those nuts.
PS - I still think you are mis-identifying bolts and nuts.
Joe Valinoti
S/V iL Gatto NS30U #221
Sea Harbour YC
Oriental, NC USA
Ralph: These type of sockets are available at any auto parts store and probably most hardware stores as well. The two shown are by Snap-on tools and probably the best available. It’s important that you soak those nuts in penetrant overnight. If you have to, make up your own spray tubes and just spray the hell out the whole area. You can’t hurt anything.
Joe Valinoti
S/V iL Gatto NS30U #221
Sea Harbour YC
Oriental, NC USA
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[/details]Hi Paul;
Thanks for the suggestion. I did try a couple of the universal joint doohickeys. I still couldn’t get the socket into a vertical position.
I’m starting to bend to the position that; despite my efforts to be more self reliant and “salty”; I am just in over my ability level here. If I can’t figure out how to get the two end covers off with the manifold still in place I am going to have to try and find a mechanic.
Ralph: If everything is disconnected on those end covers, use a hammer and knock them off. Prying is not going to do it.
Joe Valinoti
S/V iL Gatto NS30U #221
Sea Harbour YC
Oriental, NC USA
Hi Ralph
I installed my manifold yesterday. It was difficult because of that one nut however it was my fault because I left the correct 3/8 drive ratchet at home. Jill went and asked around at the marina and borrowed one which worked and saved the day.
I’m at home now but I should have measured the socket and extension and ratchet lengths used. Sorry. Or at least taken a photo.
Joe is right a 1/4 drive ratchet would work but the socket unless its a deep socket also needs an extension, and the ratchet head itself can’t be too fat or it won’t fit in the space between the exhaust elbow and the silencer. A guess would be total length of the socket+extension 40 to 45 mm, the ratchet head can’t be thicker than 20mm but thinner would make this easier. I’ll measure exact length tonight.
Three nuts can be put on the studs from the front of the engine. The same socket extension ratchet combo work on these.
This fourth nut is much easier to get at, even though you still can’t see it, from the back. My heat exchanger and the hoses were also off at the time so it made it quite easy because from here you can see the gap between the silencer and the exhaust elbow where the ratchet handle must go.
A universal joint in my opinion would just make it harder. And it might make the total socket extension length longer than 45mm. I wish I took a photo.
I put a little high temperature anti seize (like peanut butter) on the washers and stuck them on the studs before trying to get the nuts on. This worked very well.
I used the longer 1 1/2 inch studs and they made the job easier and everything fit no problem. The 1 1/4 inch are too short and I could not buy the original length studs that are 1 3/8.
Now that I did this once it would be much easier the second time.
Tom
Ralph
I just read this post after I posted about the sockets.
If you have removed the ten nuts on the ends of the three aluminum pipe fittings the end plates should have come off fairly easily.
The two end plates are (at least on mine) not glued on just a gasket.
They didn’t want to come off because the iron pipe plug and the iron exhaust pipe were so rusted that it looked like they and the end plates were rusted together. So much so that I thought they were screwed into the end plates. They are not, there is a 1/16" gap. The plate will come off with a little persuasion.
I think that if you have gone this far you have to get the manifold out to work on the studs anyway. Im really sorry I didn’t take measurements or photos of my ratchet yesterday.
Tom
Splashing at 3pm today. I was last out in the fall so I’m blocking a hundred other boats and they want me in now. Project list is still a yard long.