Posted by 1 Dollar on February 13, 2011 at 20:05:05 from (24.12.4.50):
I've read the archives on broken stud removal and it seems the two best methods are drilling and welding on a nut.
In my situation it's an exhaust manifold stud on a Allis WD45. It's a friend's tractor, and it's about an hour from my shop/tools. I usually don't do mobile maintenance, I'm just helping him. His workspace is pretty primitive, so I'm trying to avoid any more extra work here.
This 3/8 stud is broken off clean with the head. I'm leaning towards drilling it/careful easy out right now because it is smaller, and with it being flush I think it will be hard to weld a nut to it. I'd have to use a small (low-quality) flux-core MIG welder to make the weld, since I'm mobile.
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