Broken Exhaust stud in head **UPDATE**

[Skyview69]

I have a broken Exhaust stud in the head   Any ideas to get it out?  I took it to a machine shop and he could not get it out but it also looks like he didn't even try....he suggested taking it to somplace with a EDM machine but I don't have cash for that.  

Any other tips?

[Cooter]

I assume the head is off the engine, as you "Took it to a machine shop"...

I have drilled the stud first, then applied a little heat with a torch and gotten them to trun, but it was a LONG, drawn out process..Be prepared for it take a long time if it comes out at all...

[skyhawk61]

I have a broken Exhaust stud in the head  Any ideas to get it out?  I took it to a machine shop and he could not get it out but it also looks like he didn't even try....he suggested taking it to somplace with a EDM machine but I don't have cash for that.   

Any other tips?
      You can most likely get it out with an electric drill and a "left-handed" drill bit. (The bit is designed to work with a normally reversed rotation)
Use lots of penetrating oil and be sure to drill straight. As the drill penetrates, the broken stud will usually back itself right out.  I've done these on the car...had to drill a hole in the fender well, but the broken stud came out. You can get the bit at most machinery supply stores

[FLG]

Did it break nearly flush??

If so, take a flat fender washer (the washers that have a big surface area) weld the washer to the stud, than weld a nut to the washer. Go slowly, tight first than loose slowly working the stud out. The weld might break, if so just go at it again (the heat will help get things loose) worked for me quite a few times...

[Rolling_Thunder]

been there...     done that.....        Drill and apply heat...     sometime heating it and using wax will help

[Skyview69]

Yes the head is off the engine. The break is not quite flush...the stud is a hair below the surface.  I'll try drilling it out with some heat and hope for the best.  Thanks again for the tips 

[FLG]

Even if its not quite flush the welding will work, it wont stick to the cast iron

[71wrenchhead]

ive used that welding a washer and nut trick a bunch of times, works really well!

[Skyview69]

The washer and nut sounds like a good option.  hopefully I will get to it htis weekend.  Thanks again...i'll keep you posted 

[Skyview69]

I was able to get to work on the head last night.  First we tried the drill routine...man the drill barely put a dent in the broken stud 

So we decided to try FLG's tip with to weld a washer and nit to the stud....   

THIS METHOD REALLY WORKS!!!  THANKS FOR THE TIP!!!!  It took 15 minutes and on the third attempt the broken stud unscrewed with ease.  Thanks man!!

[FLG]

Glad to hear it 

[Charger-Bodie]

 

[tan top]

thats good to hear !!


that way has worked for me many times

[john108]

Hi
Would someone please post a picture and explain how to do the "weld a washer and nit to the stud"

Thank you

[FLG]

Just as it sounds,

You take the washer and place it over the broken stud, start welding in the hole which causes the washer to get welded to the stud, than weld a nut to the washer that you just welded to the stud. Than take the correct size wrench and start turning the washer/nut combination you just welded to the stud.

Heres a video i found,

http://www.youtube.com/watch?v=6T0qegbNlnY

Everyone has a different technique, as you can see the screw is very small so i would have done the same and welded the nut right to the broken stud. For the larger ones like on the heads i find it easier to weld the washer on there first  (more so if you dont have a helper) because you can tack the big washer on there and than weld it up where as the nut tends to be a bit more difficult at times, but if you wanted you could weld the nut right to the stud.

[john108]

Thank you FLG
I recently tried that with one of the Harbor Freight wire feed welders.  It didn't melt the Bolt or Nut.  It acted like a solder joint and broke quickly.
Not enough heat. I had about 1/4 in of the bolt sticking out and placed a nut onto/around it, but failed.

[Skyview69]

We welded the washer first and then the nut to the washer.  We did it three times because the first two tries they broke right off...but on the third try it worked like a charm...i think mainly because the heat finally soaked in and loosened up the stud. Like I said...only took 15 minutes. 

[FLG]

We welded the washer first and then the nut to the washer.  We did it three times because the first two tries they broke right off...but on the third try it worked like a charm...i think mainly because the heat finally soaked in and loosened up the stud. Like I said...only took 15 minutes. 

It usually takes a few times, get the nut glowing red..all the heat from the welding is what frees things up.