Hot Rods Broken off studs in Aluminum.

Hi Guys, I was sooo impressed yesterday! I had 3 broken studs on some aluminum heads. The first one I tried to heat, drill with L/H bit, chip out, etc. Of course I did mess up the threads (but it will be ok). After cryin and whinin about that I slept on it and watched a YouTube video about welding a nut to the studs. I thought that wouldn't work before as the studs were broken off about 1/8" below the surface. But as guy on video showed, I could weld up a bump on stud with mig wire and then weld nut to that. Vawalla!! Works great!! Got those 2 out in a half hour with no damage to head. I know lots of you guys have done this before. I just wanted to let the guys who never have what a miracle repair it is!!

 

It's spelled VOILA. Glad you got them out.

 

Very common practice on newer stuff. I won't go into detail, but a popular newer Chevy engine with aluminum heads has an issue breaking exhaust manifold studs. This is the common removal practice. Perhaps that makes it YouTube material? But it also works on our old stuff. Aluminum is aluminum after all.

 

It's the heat what does it.....

 

I use that method with great results but I wait until the part has cooled completely down. If you try to get it out before it normalise they tend to snap off. It works on 10-32 bolts just takes a little practice and patience . Frank

 

I've done it many times, but you need a good supply of nuts. It doesn't always work the first time. However, it has always worked in the end.

 

On the stubborn ones it might take 2-3 tries.

 

Try to use un-plated nuts. Cadmium gives of dangerous fumes.

 

Take your zinc or other plated nuts and put them in some white vinegar overnight and the plating will be gone. You are correct about welding fumes.

 

Muratic (pool) acid, removes the plating in seconds--- but do it outside near a water hose to flush off.
True about the welding fumes, if you are doing it for hours, but a 1 time shot for 2 seconds is no big deal

 

I can't remember the last time I drilled out a broken bolt. I have been doing the welded nut trick ever since I bought a MIG about 20 + years ago. In fact I used that trick to remove some wheel locks on my OT daily when I stripped the key socket.....I guess I'm too torquey.

 

I had some broken bolts for the inspection cover on a SBC aluminum bellhousing. Used TIG and built up the broken piece. Grabbed that exposed ball with small vise grips and unscrewed it. Heat did it.

 

timely thread, thanks!

just used that technique this morning, only because you reminded me that it works.

 

I know it seems counter intuitive but after welding nut try to “tighten” the bolt/nut whatever it turns sometimes just a few degrees and it seems to break loose he threads. Also a sharp rap on the broken stud/bolt with a punch and hammer before welding nut helps to break threads loose. Your mileage may vary.