Looking for ideas on broken stud removal

[av8or3]

What you are looking at is an exhaust stud broken off below the surface in an otherwise serviceable 66mm 090 cylinder. How would you remove it?

 

[timg]

Jim, My suggestion is drill out to maximum size without disturbing threads. Very small lengthwise ball burr straight line of remaining piece lodged. Bring out with gouge or pick. Remainder of thread should stay intact if you lucky sir.

 

[heimannm]

I have had some success using a small end mill to create a flat surface, then drilling the broken bolt/stud enough to get and easy out started. Heat and penetrating oil are useful as well.

If they are really hard, a carbide burr may be required.

Mark

 

[Shane¹]

View attachment 486628
What you are looking at is an exhaust stud broken off below the surface in an otherwise serviceable 66mm 090 cylinder. How would you remove it?

I'd weld a flat washer to it then a nut and I bet it will spin right out

 

[singinwoodwackr]

View attachment 486628
What you are looking at is an exhaust stud broken off below the surface in an otherwise serviceable 66mm 090 cylinder. How would you remove it?

I’ve had good luck with making a good center point with a good center punch and/or a small burr. Then, carefully drill out the center with a small, 1/16” or 3/32” carbide bit. Then, step up a couple sizes, enough for a small easy-out.

That said, I would first soak that thing in PB-Blaster overnight. Looks like a fair amount of corrosion there.

 

[EFSM]

I'd weld a flat washer to it then a nut and I bet it will spin right out

^^^^^^^This 100%. Welding onto them gives a heat shock that breaks the corrosion and rust loose.

 

[singinwoodwackr]

^^^^^^^This 100%. Welding onto them gives a heat shock that breaks the corrosion and rust loose.

Assuming the Al doesn’t melt too badly
Or, is the melting point high enough to prevent that?

 

[EFSM]

Assuming the Al doesn’t melt too badly
Or, is the melting point high enough to prevent that?

That doesn’t happen if the welding happens quickly enough.

 

[singinwoodwackr]

That doesn’t happen if the welding happens quickly enough.

Bzzt…done

 

[Jusgunn3]

Reverse drill bits and easy outs…

 

[legdelimber]

Arcing is one issue with something getting hung. But you'd be amazed at how well a layer of oxide/rust can impede heat travel for a little while.

 

[SimonHS]

Reverse drill bits and easy outs…

This.

Deep centre punch mark on the stud. Don't try a handheld drill. Clamp the head on a drill press. Run the drill in reverse with a left-hand drill bit. Sometimes the drill bit will grab enough to rotate the stud out. If not an easy-out will do the job.

 

[Duane(Pa)]

Nothing to add to the removal suggestions. I'm subbing to the thread. Don't stress too much about wrecking the threads, a Time-Sert will save the day (quite easily, I might add).

 

[EFSM]

Nothing to add to the removal suggestions. I'm subbing to the thread. Don't stress too much about wrecking the threads, a Time-Sert will save the day (quite easily, I might add).

And they will make the threads significantly stronger.