Ever need to remove a broken bolt or stud?
Studs and bolts in cast iron exhaust manifolds engine heads tend to freeze up from years of heating and cooling….expanding and contracting.
when an ez-out wont work, tig welding is an option. Sometimes its the best way.
this video shows one way to remove a broken stud.
Having a tig welder comes in handy for repairing all kinds of things… more than you can imagine.
…not just removing a broken bolt.
I have seen eyeglasses , titanium car keys, teapots, grammas old cookie cutters, cappuccino makers, pot metal window trim from old cars, boat props, garden tillers, etc…
….all repaired using a tig welder.
Having a tig welder can make you a lot of friends…Some of which you dont want. Especially the ones that have a five minute weld job that turns into 5 hours because they tried JB weld first.
In this video, A cast iron exhaust manifold wandered into the shop with a broken stud.
Since it had a drilled out stud with a broken ez-out lodged inside, I figured I would try getting that out first.
oops…it broke off.
so next, I just welded the ez-out , stud and all using 309 stainless tig rod.
309 has a pretty high chromium and nickel content that prevents it from hardening….and its pretty cheap compared to nickel rods.
after welding another nut onto the mushroom head of weld metal…and applying some heat with an oxyfuel torch, The Broken stud broke loose and surrendered.
It seems like it always takes 2 attempts for me. It is a rare occasion that a broken stud or bolt in a cast iron exhaust manifold comes out on the first try.