Posted by Scott Rukke on January 14, 2008 at 17:17:38 from (67.183.230.71):
In Reply to: Broken Stud posted by w6tractor on January 14, 2008 at 16:55:14:
Here is what I had to do recently. If there's not enough to grab then grind them flush. Use a center punch and be sure you get the exact center and punch the stud. Then drill them out starting small and graduating to the next size bit each time. On one an easy out eventually brought it out but on the other I had to keep drilling larger until the hole was just smaller than the original threads. Then I used a pick to try and pull the remaining pieces out. I ran a tap through it and it worked fine. The last one I ended up using a heli-coil. If you're not familiar with them you just drill the thing out and then tap it one size larger and thread in the coil. It acts as your new threads. This was on a head bolt torqued to 90 pounds so they hold good. Heli-coil kits come with the tap and couls and insert tool but not the drill bit. I had to use a Dremel periodically too. It was a bit of work but all turned out OK.
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