Topic: broken *&^%$# cylinder stud

[paddy paul]

Murphy's law strikes again, This was the last stud I was pulling, I cut a notch in the top, heat ,impact screwdriver, nothing, now I don't have a flat surface to drill, to get an easy-out in it, afraid to try to cut it down because I don't want to get into the engine case, pissed off, any suggestions or ideas would be appreciated.. Thanks

[MCRider]

That's a nasty break. I had one about like that, took it to a machine shop. They welded a rod to it and turned it out. But they said they had to really heat the cases a lot. I can't tell if yours is till assembled or not. Best if it was just the raw cases probably.

[mystic_1]

Welding a nut to the stub may be the way to go, at the same time it puts a lot of heat into the area and that may help too.

mystic_1

[paulages]

if one's gonna break, it's always that one. the worst one i've had to deal with eventually had to be drilled out completely and an insert installed. DO NOT try to use an easy out. i'm guessing you're going to have to drill it out.. make sure you center it perfectly.

[paddy paul]

The cases are not assembled, I was thinking  about the welding the nut on route and I think I will try it, It's just unbelievable that was the last one , all the rest came out without a problem, maybe being the one on the outside,more exposure, heat, dirt, whatever, caused it to be a little more tight than the rest, I will get it..

[MCRider]

The cases are not assembled, I was thinking  about the welding the nut on route and I think I will try it, It's just unbelievable that was the last one , all the rest came out without a problem, maybe being the one on the outside,more exposure, heat, dirt, whatever, caused it to be a little more tight than the rest, I will get it..

My broken one was a set of cases I bot from eBay. Someone else had done it, but coincidentally it was the same one.

Welding a nut on sounds like good idea.

[paddy paul]

Thanks all...

[Patrick]

Same thing happened to me when I rebuilt my K0 750 a couple years back, Paddy. Last stud, same stupid stud. Snapped flush to the case. I took it in to a machinist I knew and he got it out with a drill press and a left hand bit. I think those outside studs get more corrosion and dirt than the others. Good luck with it.

Patrick

[Seamus]

I had a similar problem. There was a little bit sticking proud of the case, so we welded a flat piece of steel with a hole in it onto the stud and turned it out. Worked brilliantly. Used some material over the case to keep the worst of the heat off and the heat of the arc weld loosened the stud. Just turned it out.

Worth a go if you have enough metal sticking out of the case.
Good luck
Seamus