Topic: F@%K!!!! Snapped cylinder stud... now what?

[timdhawk]

Got 15 of the 16 out without any issue and the last one snapped off 1/8" from the mating surface!!!!
Any ideas how to get it out now...

[domer]

vice-grips, a six pack and a prayer.

[Popwood]

Ouch. Sorry for your trouble. I doubt a vice grip will get enough purchase to get a turn on it. Your next step would be an "Easy Out". Do you know about these? Drill a hole in the stud, the Easy Out is reverse threaded so you drill it in, it grabs, and you can remove the stud. Problem is, it's not as "easy" as it seems, but it is doable. Recommend you use the biggest size the stud will take. Instinct says use a smaller one, but your risk snapping it off in the stuff -- don't ask how I know. I had a DeWalt snap off and it may not have happened with the next size up. There are other posts on the forum as it's happened before, believe it or not. If I remember, heat helps, and PB Blaster. Don't be in a hurry. Hit it with PB Blaster and let it work overnight, do it again and give it another overnight. Patience is worth a lot here.

[bikeme2001]

You could take it to a machine shop and have it drilled out.I got one snapped off and I think I will try that route next.Heat and lube may help.No open flame thou.I have used ez outs and if you drill to big the ez out will expand the broken stud and make it all but imposible to get out.A machinist can lock the piece down and drill it out in a bridge port.

[markb]

Heat has always worked for me.  I use an industrial heat gun but even a hair dryer should help.  Try to direct most of the heat to the casting.  I do it for several minutes.  If it still doesn't come out I'd soak it with PB Blaster, wait a while and then try again,
Good luck,
Mark

[SOHC Digger]

Although I've never tried this on cylinder studs, I have extracted many broken bolts by welding a nut to the remaining part sticking out of the hole, letting it cool, and removing with a wrench.  If that doesn't work, cut a slit in the top of the broken stud and use an impact screwdriver on it, being careful not to damage the case.  Heat will help all of these as the aluminium casting will expand more than the iron studs.  If all this fails, you always have helicoils to repair the hole if it becomes enlarged from drilling out the stud.  Good luck.  Let us know what works.

[gregimotis]

If it were me, and I only had an eighth inch to play with, I'd try a little heat and solvent, then call a pro and find out what he charges.  No doubt less than a buggered bottom ...err, you know what I mean...

[nippon]

http://forums.sohc4.net/index.php?topic=17206.0

[mcguiver7]

http://www.sears.com/shc/s/p_10153_12605_00952168000P?vName=Tools&cName=Auto&MechanicsTools&sName=Taps%20&%20Dies&psid=FROOGLE01&sid=IDx20070921x00003a

i've used these to remove head studs from a 911 block that were more stubborn than you could ever believe. These things are amazing none the less. just make sure to heat the stud for a few mins to burn up any loctite and to expand the metals.

[timdhawk]

Thanks for the replies so far...here is what I'm working with. I need some machine shop stuff done anyway, so I think I'll try that route first.