Broken stud, help...

[Ed]

I was removing the studs from my head. After letting them soak in WD-40 I go to remove them. They all came out except for one. It broke. So I said to my self "here I go again" as I was having flashbacks. So I drilled out the center and proceeded to use the easy out. That broke too. I took out the dremmel tool and cut a slot on the tip of the bolt for the impact screw driver. I ended up breaking the tip off the bit. This bolt does not want to come out.

Does anyone have any suggestions on what I could do next. I tried drilling it out again but a piece of the easy out is stuck in the center (hardened steel) of the broken stud.

[kmack]

Unfortuntely, you're most likely stuck until you can get the rest of the easy-out out of there.

Get a small point punch and use it to try and break the rest of the easy-out into smaller pieces that you could then work out of the bolt. You'll never be able to drill it until the easy-out is gone.

I've done this before. You need to keep hammering on the easy-out (or what's left of it) to try to shatter it. Breaking it up will loosen its hold on the bolt allowing you to remove it. You may need to get a small pick to help get the pieces out.

If you're hole is centered in the bolt (once the easy-out is out of the way), then you can then get started to drill it out. Go to PepBoys and get a set of Heli-coils for that stud size (8mm I believe, but I don't remember the thread pitch). Get the complete set, it'll probably run about $30 but it'll have the tap you need. Get the proper drill size and drill away making sure you drill straight.

Once you get the heli-coil in the threads will actually be stronger than the original. Good luck and be patient. I had to do 3 studs on my engine last year, but then I didn't break an easy-out in them either.

[Bambikiller240]

Originally posted by Ed

I was removing the studs from my head. After letting them soak in WD-40 I go to remove them. They all came out except for one. It broke. So I said to my self "here I go again" as I was having flashbacks. So I drilled out the center and proceeded to use the easy out. That broke too. I took out the dremmel tool and cut a slot on the tip of the bolt for the impact screw driver. I ended up breaking the tip off the bit. This bolt does not want to come out.

Does anyone have any suggestions on what I could do next. I tried drilling it out again but a piece of the easy out is stuck in the center (hardened steel) of the broken stud.

If you are going to have the head rebuilt, just take the head to the machine shop and let them deal with it. They will not charge much to fix this and it will save you the headache.

On the other hand if you are just replacing the studs and are leaving the head on the block...........good luck. Follow the advice given by others, as you really only have the two options available.

carl

[beandip]

depending on what is left of the bolt , If you have room drill into the bolt next to the ezout with out hitting it , because it will snap the bit if y ou hit the hadend steel. If you can drill sucessfully around the ez out then you can knock it loose. Other wise you just need to pick around it and try and loosen it. A 1/16 " drill will work if you can get it in . Good luck

[Ed]

I tried breaking up the easy out but no luck there. I was thinking about drilling around it, but I have a feeling that the drill bit will break. Then it will just get worse. The only thing that seems to work are grinding stones. I used those small stones attached to my dremmel tool and was able to cut it down a little before I ran out of stone. This process would also enlarge the hole. Could I fill it with JB Weld then tap it? Would it hold up? Or should I have it welded then re-tapped?

I was thinking since the machine shop charges by the hour I wanted to strip the head down and have them do only the work I couldn't (seats, guides & valves). Getting that broken stud (that is now filled with hardened steel) out is going to take them a while. If they are just going to cut around it then have it welded well, that is something I could do. I think.

[Bambikiller240]

Originally posted by Ed

I was thinking since the machine shop charges by the hour I wanted to strip the head down and have them do only the work I couldn't (seats, guides & valves). Getting that broken stud (that is now filled with hardened steel) out is going to take them a while. If they are just going to cut around it then have it welded well, that is something I could do. I think.

Instead of guessing, why don't you ask them what they will charge to do it. Also, they SHOULD be able to get it out and an new one for you without buggering up your head. A definite risk that you (as one who is inexperienced this this probem, like most of us) will run.

Last time I needed this help (with broken extractor, just like yours) the shop didn't even need to helicoil the hole, they managed to get it out properly. Theyknow the tricks as they encounter this very often.

IT NEVER HURTS TO ASK WHAT THEY CAN DO FOR YOU.

Just my $.02, of course it's your money (and your head, or what will be left of it, if you screw it up)

Carl

[Ed]

Thanks Guys, I think I'm gonna let the machine shop work on it.:classic:

[beandip]

In the long run this is the best idea. That is to take it to the shop. Let us know how it works out.