Anybody know a sure fire way to remove a head stud that's broke off just below flush in a ford banger block? 54chop
Here's what worked for me on my Jeep where the head bolt busted flush with the block. I took a larger flat washer that had a center hole size a tad smaller than the broken bolt. I then welded the center of the washer to the broken bolt. The outer diameter of the washer was large enought to weld a nut to the washer. I then took a socket with a ratchet and the stud came out. I don't know if it was just the heat or what....but it came out.
EDIT: Hey, Joes50, you must type faster than me..... I've had pretty good luck with laying a big washer over the broken stud, then welding it to the stud until the puddle in the middle of the stud is flush with the top of the washer. Let it cool, then weld a nut to the top of the washer so you've got something to get a wrench on. Seems like it works for me about 75% of the time, I think the heating of the welding, then cooling helps to break it loose. For those that don't come out this way, I usually break out the drill and start drilling. Patience is key when you resort to drilling, do your damndest to get the hole centered all the way through the bolt, then drill it a bit larger in increments until you see threads. At that point you can usually pick the remaining threads out with various "pointy" things. Sometimes once you get enough of a curl of thread to grab with a needle-nosed pliers you can just twist the remaining threads out, IF you got the hole centered to start with.
easy way, drill it to the correct diameter and use a easy out or use a left handed drill bit to get it out
this is not always a good idea, most people screw up the threads when doing this and they dont have a tap to fix their mistakes, but as a last resort it might work
You stated that it is below flush with the block. If you cant weld something to it you will have to drill it. To get it perfectly centered bolt the head back on then using a drill bit that is just exactly the same size as the bolt hole in the cylinder head drill just enough to center a smaller drill bit . Also some times a left hand bit will unscrew it .Keep using progressively larger bits until just the threads are left and pick them out as mentioned before. If you make a mistake and ruin the threads no big deal cast iron is very easy to drill and tap. You can go to the next larger size head bolt the engine will never know the difference.OldWolf
We used to get these in the shop all the time. Sometimes if you tap the broken stud around it will come loose. If that is a no go, I try to tack weld a smaller bolt to it. This requires a little skill and guts, but the heat generated by welding will often break some of the rust loose. Once I have the bolt welded to the stud I immediately spray some PB blaster or similar lubricant around the stud. The cold penetrating lubricant creates a bit of a thermal shock that will displace more rust etc. Make sure you do not force the bolt, rather work it gently in both directions. Good Luck....
This is what I do too. But if the bolt is big enough after drilling a small hole I use a Dremel with an 1/8 inch end mill and work my way to the edge of the threads, thn go 180 degrees and repeat. Usually you can collapse the pieces and remove. Remember PATIENCE!!
The Jalopy Journal
