wing stud repair

[DoubleDlover]

 
Wow what a nightmare.... Not 1 but ALL 8 studs were broke off.  But i got it done. As you can see from the pics. You cant just drill strait into  the bosses. You will screw the pooch on that one. There angled to match the way they go into the 1/4. Very important.  And it was a MUCH better fit using a drill size one smaller then what was recomended before tapping.

[DoubleDlover]

more pics

[DoubleDlover]

last

[moparstuart]

 

[Hemi Runner]

Was that the wing that was on ebay recently?

[WINGIN IT]

Great job !
I've never had good luck with broken studs and tapping, you made it look easy 

[DoubleDlover]

oh boy. it wasnt super easy. The part moved on one drilling and the drill bit broke off in the stud. So i had to buy a cobalt drill bit bigger and drill it out. Keeping that angle is really hard. As long as you go slow. Take your time. Check and recheck. it should be ok.

[hemi68charger]

Good job ... 

[Highbanked Hauler]

Great job !
I've never had good luck with broken studs and tapping, you made it look easy 

same here, plus a steel stud in aluminum 

[Mopar John]

Thanks for sharing! The pictures are a big +!
MJ

[DoubleDlover]

not a problem. The problems started because they put steel studs into aluminum. So that electrolious crap seezed them in. But with the heli coils they are stainless inbetween the steel and aluminum. So it should work better.

[WINGIN IT]

...The part moved on one drilling and the drill bit broke off in the stud...had to buy a  bigger drill bit.. and drill it out ... Keeping that angle is really hard...

Ok now it sounds like what happens to me   


Are all the studs the same size? In that one pic the closest one to the camera seems pretty big compared to the rest . Wasn't sure if it was just the camera angle or what.

[DoubleDlover]

Hi yes. all the same size length wise. But i have a feeling the ones that the braces bolt to might be a little longer maybe? does anyone know the correct length for each stud? one more thing. You really have to make sure you drill the metal stud really close to down the center. Ir your off by to much. when you drill the final big hole. it will walk on you. Because steel is harder then aluminum. It will push the drill of to the side and your hole will not be in the right spot.

[daytonalo]

I have had this exact issue many times over the last 35 yrs , simply clean end of stud and then proceed to weld a non-plated nut over stud . You weld thru the nut with a decent heat setting  then work back and forth .

[moparstuart]

I have had this exact issue many times over the last 35 yrs , simply clean end of stud and then proceed to weld a non-plated nut over stud . You weld thru the nut with a decent heat setting  then work back and forth .

the heat helps break it loose too ,  we do it all the time on used motors with alumiinm heads and exhaust studs broken off

[DoubleDlover]

yes you are right. I did try that first. 2 of the studs actualy were sticking up 1/4 inch. So i was able to actualy screw a nut on 1 turn and then weld it on a high heat setting. it DID break it loose. But it would only turn a 1/4 turn before totaly locking up again for some reason.. And then the stud would shear off. So i kinda didnt have a choice this time...