Topic: Removing a broken stud

[eigenvector]

I have an exhaust stud that broke off INSIDE the mounting hole.  About a 1/4" inside.

How would you go about removing that?  Would an easy out work here or is that too far in the hole for something like that to work?

[70CB750]

I have never seen an easy out that worked. Get a left hand drill bit and try to drill it out, chances are it will spin it out.

[MCRider]

Agreed, never seen one work. Problem as I see it, when you turn an EZO counterclockwise to remove the bolt, it expands the bolt into the hole and fights against itself, breaking almost always.

A reverse drill removes material while coaxing the broken piece to rotate in the correct direction. And short of that, simply drilling it out, little bit at a time, often works. Getting a good start is the problem, especially when as yours is the break is down in the hole.

OFten the threads will be destroyed calling for a thread repair.

[eigenvector]

I'll take a look at finding a reverse drill then. 

I'm going to take a bit of time off, I've made big strides today - don't want to F it up by rushing forward.

I removed the rest of the studs since I have to order a new set anyway.  I was amazed how simple they came out. 

[chewbacca5000]

Harbor Freight sell the reverse drill bits.  I have used them and they work.  Make sure you have a centre punch to keep the bit from wandering.  Be sure to us a bit that is alot smaller than the stud.  Drill and if it comes out great.  If not go to the next size up.

Is it in a location that you can get at square?  An angle will not work.

[70CB750]

The best way is EDM, but new used head would be proly cheaper than that.

[Airborne 82nd]

You might want to get this. The first step is the most important one. so is the tool.  (self centering drill bit)
http://www.homedepot.com/s/self+centering+drill+bit?NCNI-5
This is just the first one that pooped up. I go with quality first. So pick your weapon of choice.

[chewbacca5000]

You might want to get this. The first step is the most important one. so is the tool.  (self centering drill bit)
http://www.homedepot.com/s/self+centering+drill+bit?NCNI-5
This is just the first one that pooped up. I go with quality first. So pick your weapon of choice.

Those look pretty nice.  Are they a drill bit with a sleeve?  How do they self centre?

[70CB750]

They look like drill bushing attached to a bit, great idea.

[grcamna2]

I've got to learn that if it's at all possible to flatten the broken bolt/stud on the end as much as possible before I drill STRaight.     been there done that. 

[chewbacca5000]

I've got to learn that if it's at all possible to flatten the broken bolt/stud on the end as much as possible before I drill STRaight.     been there done that. 

I had a broken stud problem once, but not in the hole like op.  Was able to weld a large nut to it and use a screw driver as a handle to get the stud out.

[koendd]

I've never had success with drilling holes and reversing them out...

I had 3 studs breaking when removing them from my cases.
one of them was inside the cases as well, I just welded on it till the welds got "out" of the case and the welded a nut on that.

then let it cool down and used a impact wrench to get them out.

good luck 

[eigenvector]

I have it worn down at this point.  I'll see if I can use a 6mm tap to get the threads back in shape, barring that I might have to oversize to 8mm and open the exhaust clamp hole to 8mm.  Not my first choice of course but I don't even see evidence of threads in this hole - almost looks like it was welded.

Incidentally - Speed Out, you know those drill bits that back out stripped screws?  Useless as a third nipple.  Might work on stripped screws - but hardened bolts, nope.

[markb]

The best way is EDM, but new used head would be proly cheaper than that.

Agreed, EDM is the best especially when it's below flush.  I've paid between $25-40.  Maybe you could get a used head for that.  Best part is no headache and only time spent is dropping it off and picking it up. 

[70CB750]

That is a good price, i never had to research it. Good to know.