I have a broken manifold stud on my block. I'm having a hell of a time getting it out and the drag races are coming up this weekend. I've tried a super out extracter which broke off in the broken stud. No drill bits seem to be doing any damage and I've tried everything but solide carbide. does anyone have any suggestions on how to get this out? I'd rather not throw it together minus one stud and have an exhaust leak..

 

Amateur mistake using a drill-in broken stud remover, but that's ok. Depending on how much meat is sticking out, you can use a real stud puller like this one from Harbor Freight tools



THE absolute best way of getting a broken bolt out is with a nut and a welder. Place the nut over the broken bolt and weld the inside up to make a new bolt head. This does 2 things : 1) Gives you a nice hex-head to grip so you can remove it with a wrench, and 2) it heats the entire bolt up and breaks any bonds the bolt has with the block.

If none of these options are available, then a pair of vice grips and a plumber's torch will work. Just don't melt the aluminum.

 

the stud broke off inside the block, there is nothing to weld to. pretty much my only real option is to drill it out but every bit i use on it doesn't seem to do any damage. Someone told me last night that spraying it with butane then hittin with a drill would make the bolt shatter. can butane really do that to a bolt?

 

It could. If you heat the bolt up then spray with butane it may work. But you will also weaken the surrounding metal and threads.

There aren't too many options left. With the stud extractor in there, drilling out is going to be near impossible.

Call around to the local mechanics and see if they know of a machine shop with an EDM stud removal machine. They can electrically erode the stud if there is sufficient access but it means bringing the car over to the shop. Won't be cheap.

 

If you have access to a stick welder my fav way to remove broken stud is to weld the stick to the end of the stud(you have to be precise with this one) and then use vise grips to lock on the stick and spin the stud out.

 

Is it broken flush with the block, or a little ways IN the block?

 

its broken a little bit inside the block, so i cant weld to it very well and i think i got most of the stud extractor out. I think it may be cold fused inside because any the weld i could get on it just broke off and the stud extractor wouldn't even turn the bolt. and if i heat it up then hit it with butane, will that not catch fire?

 

You've got to remove the e-z out from the stud to drill it out. Freezing and shattering the extractor sounds like your best bet. I'd use liquid nitrogen rather than butane tho. Use some good eye protection for this! Drill out the stud (carbide bit works great for this but is not necessary.).

Then install a thread insert (Helicoil) since you're probably going to maul the block threads in the process.

 

I dont think liquid nitrogen is readily available around here?

 

I purchsed these for all the broken bolts on my rusy undercarage(sp?).

http://www.qbaroo.com/quikcentercom/...&subcategory=3

You can screw them down into the bolt hole.

Very well made and I give 4.5 stars

 

i dont have any stud showing. it broke off inside the block a little.

 

You can use dry ice for cooling also. Good grocery stores will have it. Of course if you've really removed the carbide EZ-out remnant you can get straight to drilling.

 

I am doubtful that you're going to shatter anything. Sounds like pretty wishful thinking.

Your best bet is to drill out the whole business and tap/helicoil the right size in. That involves drilling into the aluminum around the stud a bit...if you do that, I bet you could get it out. Buy a nice drill bit and be careful.