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How do I remove a broken stud from aluminium?

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Don

06-15-2003 03:40:11




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I have sheared off a bolt while removing the aluminium thermostat housing, fortunately there is enough sticking out to get mole grips on but the bolt is completely stuck solid (1/4"). i would be really grateful if someone has some advice on how to remove it as I really dont want to drill it out. Thankyou for your help




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ROLLIE

06-28-2003 17:48:28




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 Re: How do I remove a broken stud from aluminium? in reply to Don, 06-15-2003 03:40:11  
one way is if you are a welder--put a washer--the size of bolt -over it-weld washer to bolt-now lay nut on top of that-- weld nut to washer--now you are ready to take bolt out-- the heat should help- so wil praying-- good luck



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buck

06-16-2003 07:38:17




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 Re: How do I remove a broken stud from aluminium? in reply to Don, 06-15-2003 03:40:11  

Having worked on many a VW engine I found a few methods that work well. first get the top of the brken stud fairly flat and then strike the head fairly sharply.this will tend to loosen the stud in the casting. Now drill two small holes side by side to act as a a screwdriver slot to remove the stud. Should this not work then there are step up or step down studs avilable that will make the repair. Just drill out the entire stud and tap to next larger size or drill in the stud and tap for smaller size.Check with NAPA or your local machine shop for the studs.A typical one may be 9/16 on one end while being 1/2 on the other. good luck--these types of repairs can be dfficult. Tip: If you are doing a lot of work dealing with removing nuts and bolts and especially the ones that tend to break always use impact tools to do the loosening as the vibration of these tools greatly reduce the number of broken studs/bolts etc.

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