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Broken off stud removal

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Hal/WA

02-24-2003 18:14:52




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I had the misfortune of somehow breaking off the little stud that holds on the air cleaner and its cover on my Stihl chainsaw. To make it worse, the broken off part was about 1/4" down inside the alloy casting of the carb, and broken off flat. I tried to use a screwdriver to coax it out, but there was nothing for the blade to catch. I thought about using an "easy out", but would have to drill the broken stud to do so and thought that it would probably strip the threads in the casting. I applied penetrating oil and let it sit.

I remembered buying a tool kit called a Screw-Out at Sears a couple of years ago, but had never used it. It works like a drill bit that cuts when it is turned counter-clockwise. The smallest bit in the kit worked like a charm. I just put it into the chuck of my cordless drill, reversed the direction the drill turned and put the point down into the hole in the casting. The point contacted the broken stud, caught on it and removed it in about 3 seconds. The threads in the soft alloy are fine.

The kit cost about $20, with 3 different sized bits. I have had a terrible time removing broken off bolts and studs, especially in blind holes. From now on, the Screw-Out is the first thing I will try, at least for small diameter jobs. For larger broken off bolts or studs, I plan to try reverse twist drill bits.

Just thought I'd pass on a "it worked for me".

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Bill Smith

02-26-2003 23:41:53




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 Re: Broken off stud removal in reply to Hal/WA, 02-24-2003 18:14:52  
I am not going to elaborate a great deal. On smaller diameter stuff, and twisted off down inside hole I would have to agree. On larger diameter stuff and twisted off flesh or even down inside a little (especially on heavy casted parts such as a block) I am in favor of welding nut onto broken stud and getting on it with a wrench and scrapping all other options. But when that is not possible, such as in your case, that might be the best way to go.

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Duke(WNY)

02-25-2003 15:53:36




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 Re: Broken off stud removal in reply to Hal/WA, 02-24-2003 18:14:52  
On small screws and bolts that are broken off flush the first thing I try is an electric engraving pencil. (The kind you use to put your name on tools)Been a locksmith for thirty years and have salvaged hundreds of mortise cylinders with broken screws. Get on the edge of the screw and hammer in the unscrew direction.



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Dan England

02-25-2003 08:27:46




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 Re: Broken off stud removal in reply to Hal/WA, 02-24-2003 18:14:52  
Sears also makes "Bolt Out" for removing bolts. I have used them to remove bolts around battery box and seat pedistal which were really rusted tight. Had good results. Several other Cub owners have also reported good results. Cost is $19.95 for set of five.



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Ray,IN

02-24-2003 18:31:39




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 Re: Broken off stud removal in reply to Hal/WA, 02-24-2003 18:14:52  
For many years left hand drill bits have been used for stud, bolt, screw removal just as you describe. Left hand drill bits are readily available in the same sizes as right hand bits including metric.



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