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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.
WE fix.
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.
( As always, feel free to visit us at our sister site, WeldingTipsAndTricks.com. )
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June 15, 2016 at 2:49 PM
Regards for helping out, wonderful info.
March 2, 2013 at 10:45 PM
Hi Jody,
I just finished taking a small engine and farm equip. repair course and mentioned to a couple of old farmers that I had 4 bolts break off on my kubota exhaust pipe and was having a hard time getting them out. They said it was very simple. Heat the broken bolts red hot and stick a wax candle to the bolts. The heat sucks in the wax and lubricates the threads. When they cool, you can screw them out with your fingers. Haven’t tried it yet but will when I am able to get to the shop.
I’m 67 years young and have just started a five month college welding class and love it. Can’t thank you enough for your great tips and tricks. My teacher says he would really like to meet you someday. So would I!!
May the blessings be,
Allan
January 26, 2013 at 8:18 AM
Great video! How do you generally price these jobs being that each siutation is different.
Some might take more time,less time,etc. Thanks! -Frank
September 4, 2012 at 8:59 AM
great video
July 20, 2012 at 5:11 AM
I had a broken off bolt in an aluminum head. Totally forgot that I had my mig stuffed in the corner, as I’m in the middle of moving and have already relocated my tig. Luckily I had enough bolt sticking out to place a nut over the end.. Followed this to a tee and had 0 issues removing the bolt on the first try. Beats having to take the head to a machine shop any day.
July 10, 2012 at 7:23 PM
Must have been a glitch this end. Anyway, I got to watch it. Great video as usual.. Thanks.- Mason Boatbuilders, Port Lincoln, South Australia.-
July 10, 2012 at 6:24 PM
Hi Jody, I was really looking forward to watching this video on stud removal as its relevant to what I do in the boat building/maintenance field.
Unfortunately it comes up but won’t play.
Thanks for all your videos of the week , I really get a lot of good tips from them –actually look forward to getting them.
Richard.
July 10, 2012 at 1:45 PM
Another grand video Jody! I had an older man (Jimmy)teach the broken stud trick 35 years back which I’ve used many times. He also took a small hammer after welding the nut on and tapped the head of the nut a few times to help to brake the stud free. Again another fine video.
The Jodster