head stud removal

[Lawrie]

I had a good day today , got 47 of the head studs out of a C69A block, only one snapped off flush.
What I did was to cut them all off about 1/2 inch above the block with a 4in cutoff wheel on the angle grinder, then get a pile of old head nuts, drill them out to 7/16 and tig weld them onto the studs, after they cool, used a 1/2 drive air impact gun on the low setting, all but the one came out, this is, as any one who knows ,usually a real pain of a job, so tomorrow only one to drill and tap out.
Lawrie

[Kurt in NJ]

Tig weld a washer to the broke off one, then weld a nut to the washer, then the piece of the stud will come out

[JM 35 Sedan]

Does anyone here have experience using a magnetic base drill press to drill out the broken piece of stud while staying on center?

[JSeery]

Originally Posted by JM 35 Sedan

Has anyone considered using a magnetic base drill press to drill out the broken piece of stud while staying on center?

That would work, but there is always the chance of messing up the block. The weld on a nut method works so well and is fairly easy, IMO it would be difficult to try a different approach. The heat from the welding seems to be a major factor in the success rate. But if all else fails, then drilling might be the way to go, we used the magnetic based drills a lot when I worked in tooling and the jig shop.

[franksford]

Yes i have many times, it works well just get it centered.

Frank

[GOSFAST]

Sponsored Links (Register now to hide all advertisements)

Originally Posted by JM 35 Sedan

Does anyone here have experience using a magnetic base drill press to drill out the broken piece of stud while staying on center?

The worst Flathead studs we've found can be drilled out using the magnetic drill press in about 10 or 15 minutes! Depends on the remaining length in the block?

We simply "whiz-wheel" the top off, leaving about 1/4"-3/8" sticking up. We have the proper tooling to aline the drill press and the stud before we drill anything?

Thanks, Gary in N.Y.

P.S. Here's a shot of the drill press ready to go! It is a very versatile tool all-around!

[Yoyodyne]

Originally Posted by GOSFAST

The worst Flathead studs we've found can be drilled out using the magnetic drill press in about 10 or 15 minutes! Depends on the remaining length in the block?

We simply "whiz-wheel" the top off, leaving about 1/4"-3/8" sticking up. We have the proper tooling to aline the drill press and the stud before we drill anything?

Thanks, Gary in N.Y.

P.S. Here's a shot of the drill press ready to go! It is a very versatile tool all-around!

The way I did it with the bushing in the head was almost that fast, definitely would be next time when I don't have to experiment and feel my way. I had no way to determine the exact center of the hole without setting it up in a machine so I felt safest with the head as a guide. Setting it up in a machine would have taken all day to do both sides.

I lust after a nice mag drill, haven't needed one enough to get one yet. There's a device that's sort of a hand powered version of a mag drill that is often called an "Old Man" drill, sometimes a Cole drill, ratchet drill etc. Here's one in use. I borrowed a mag drill to do this job, but wound up doing it the old fashioned way. I found this on Ebay and cleaned it up - might be a handy alternative for someone only doing this occasionally.

[KiWinUS]

Drill 1/8 inch hole through center of broken stud then blow out with gas torch. Too easy & never hurts threads in block. Used this method hundreds of times over the many years in many broken stud/bolt situations. Will not work in blind hole. Even works in aluminum.
Cheers
Tony

[deuce5wndw]

Originally Posted by KiWinUS

Drill 1/8 inch hole through center of broken stud then blow out with gas torch. Too easy & never hurts threads in block. Used this method hundreds of times over the many years in many broken stud/bolt situations. Will not work in blind hole. Even works in aluminum.
Cheers
Tony

This works great but pay attention to the blind hole warning!

Dale

[Ronnie]

Tig welding the washer and nut does work well. You really need a foot pedal so you can hang around on the puddle for a extended time to get a good heat sink. While cooling down quench the weld with a candle and leave it alone until it has cooled off and you can touch it with your hand.Now try to remove it. Have done dozens and haven't failed so far in 30+ tig welding. The quench can be repeated during the cool down.Hope this helps. I have done many sizes 6/32 up to 3/4"steel and aluminum.


R

[ford38v8]

I once created a thick aluminum drill guide for use on a broken exhaust stud while the engine was still in the car. Using an offset hand drill starting with a small bit, removing and enlarging the drill guide hole to finish the job. On the last pass, the broken stud threads spiraled out on the drill bit.

The weld-on nut method is demonstrated in this link:

http://www.fordgarage.com/pages/studremoval.htm

[Kurt in NJ]

It works so good it's easier to break the studs off than working for days worrying them out

[JSeery]

Originally Posted by Kurt in NJ

It works so good it's easier to break the studs off than working for days worrying them out

Yep, that's my approach, LOL.

[KiWinUS]

Originally Posted by Kurt in NJ

It works so good it's easier to break the studs off than working for days worrying them out

Exactly how I feel & that is why I like my method. I have tried most every way possible. All can still have their headaches like Lawrie has found with his last bolt. My method is no preping nuts. No welding. Just blow them babies out. Too easy & quick.
Cheers
Tony

[deuce_roadster]

When you say "blow out with a gas torch" are you talking about using a cutting head or are you suggesting an air nozzle after heating the remaining stud to the point of melting? Seems like a cutting torch would have a high probability of ruining the block. Could you describe this operation in detail?

[KiWinUS]

Originally Posted by deuce_roadster

When you say "blow out with a gas torch" are you talking about using a cutting head or are you suggesting an air nozzle after heating the remaining stud to the point of melting? Seems like a cutting torch would have a high probability of ruining the block. Could you describe this operation in detail?

Okay I will do my best to explain but must say plain old years of experience doing this is proof in the puddin for me. A liberal coating of Howes penetrant first and let it do its job as long as I can. I have tried about all penetrants & this is the best in my opinion.
I use a stud extractor next & if studs don’t come out I keep pulling until studs break. Typically close to deck level. I then center punch broken stud. Now drill with 1/8 drill all way through. Now time for the gas torch with cutting attachment. I do this outside when possible to avoid hot splatter in my shop for obvious reasons. Now fire up cutting torch & set it as you would to cut. Now put heat to broken stud. You will see due to the mass of stud versus mass of block stud heats up red quickly with no sign of red to block or threads. Pull lever for oxygen & proceed to blow molten stud out of threaded hole. You will see that threads do not even get any color in them so consequently remain untouched by gas cutting torch. You will see (use correct color shield so you can see what your doing.) once all remains of stud are gone, you will clearly see. Let cool & use thread chaser to final clean. In over 40 years of using this method I have never had an issue or damaged threads beyond their integrity prior to gas torch.
Hope this helps @ I will gladly answer any questions. If you have any experience with a gas cutting torch you will see how easy & quick with zero issues this is.
Cheers
Tony

[Yoyodyne]

Originally Posted by KiWinUS

If you have any experience with a gas cutting torch you will see how easy & quick with zero issues this is.
Cheers
Tony

What size tip do you use?

[Lawrie]

Got the last one out this morning,I drilled it with a pilot drilll out the the root die of the thread, then picked out the remainder of the stud ,came out great but took as long as getting the bother 47 out,
Lawrie

[51504bat]

The former owner of an auto parts store I trade at swore by using a reverse drill bill to drill out broken bolts. Said the reverse bill would assist in spinning the broken bolt out. Not sure if it would work on a head bolt stuck in a flathead but I kind of doubt it.

[Lawrie]

I do all the drilling after the pilot drill with left handed snap on drills.
Lawrie