The Ford Barn

tom1948 · 07-31-2023, 03:51 PM

I have the tail light housing for my 48 merc, one of the mounting studs is broken off. It's bad enough that the person I got it from started to drill it out, but it went off-center, he then tried to drill a small pilot hole in the center. The bit is approximately 1/32"or maybe smaller, the drill bit is broken off in the tiny hole. for a week I've been soaking it with B'laster and tried heating it with a torch using a small center punch to try to get it out, so far, no good. I'm afraid to heat it more as the area around the stud has started to melt. any ideas?

ford38v8 · 07-31-2023, 04:23 PM

Drill & tap 4-32 next to it, and another opposite. Screw in a couple of screws the length of the missing stud, then build them up with JB Weld, file it down for your new stud. Without seeing it, that’s my best guess.

tom1948 · 07-31-2023, 04:54 PM

Btw, the broken stud is a 1/4"-20 so there's not a lot of room to work with.

1942deluxe · 07-31-2023, 09:44 PM

tom1948, check Ebay. Don't know which side you are working on but there was a NOS LH for $39.95.

nickthebandit · 08-01-2023, 02:36 AM

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Use a socket for a backup, put the tail light housing over the socket, and hit the broken stud with a hammer to remove it. I have done this many times with Ford tail light housings, then replace the broken stud with a bolt.

07-31-2023, 03:51 PM	#1
tom1948 Senior Member Join Date: Aug 2014 Location: west palm beach florida Posts: 182	Quandary I have the tail light housing for my 48 merc, one of the mounting studs is broken off. It's bad enough that the person I got it from started to drill it out, but it went off-center, he then tried to drill a small pilot hole in the center. The bit is approximately 1/32"or maybe smaller, the drill bit is broken off in the tiny hole. for a week I've been soaking it with B'laster and tried heating it with a torch using a small center punch to try to get it out, so far, no good. I'm afraid to heat it more as the area around the stud has started to melt. any ideas? Last edited by tom1948; 07-31-2023 at 03:52 PM. Reason: spelling

07-31-2023, 04:23 PM	#2
ford38v8 Senior Member Join Date: Jul 2011 Location: SF Bay Area Posts: 6,671	Re: Quandary Drill & tap 4-32 next to it, and another opposite. Screw in a couple of screws the length of the missing stud, then build them up with JB Weld, file it down for your new stud. Without seeing it, that’s my best guess. __________________ Alan

07-31-2023, 04:54 PM	#3
tom1948 Senior Member Join Date: Aug 2014 Location: west palm beach florida Posts: 182	Re: Quandary Btw, the broken stud is a 1/4"-20 so there's not a lot of room to work with.

07-31-2023, 09:44 PM	#4
1942deluxe Senior Member Join Date: Jan 2011 Location: Albion, PA Posts: 726	Re: Quandary tom1948, check Ebay. Don't know which side you are working on but there was a NOS LH for $39.95.

08-01-2023, 02:36 AM	#5
nickthebandit Senior Member Join Date: May 2010 Location: Shippensburg, pa. Posts: 420	Re: Quandary Sponsored Links (Register now to hide all advertisements) Use a socket for a backup, put the tail light housing over the socket, and hit the broken stud with a hammer to remove it. I have done this many times with Ford tail light housings, then replace the broken stud with a bolt.