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Tool Talk Discussion Forum

Stud broke on 45 degree angle, any hope?

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Kevin2

08-23-2004 18:24:39




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This one has me scratching my head. I have an exhaust manifold stud broken off flush with the head, but also on a 45 degree angle. Is there a way of getting this thing drilled out with common tools in the engine bay? I can"t imagine how to hold the center to drill it out. Thanks for any tips!




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Loren

08-24-2004 18:38:54




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 Loose? in reply to Kevin2, 08-23-2004 18:24:39  
Have you tried moving it with sa screwdriver? If it wiggles even a little bit then it'll probably come right out. I'd go with a very small center punch and about a 6 or 8 ounce hammer in that case. Just work it around till you can get ahold of it.



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Kevin2

08-24-2004 16:04:43




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 Re: Stud broke on 45 degree angle, any hope? in reply to Kevin2, 08-23-2004 18:24:39  
All Good ideas, Thanks!



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Fred OH

08-24-2004 08:12:57




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 Re: Stud broke on 45 degree angle, any hope? in reply to Kevin2, 08-23-2004 18:24:39  
I always made up a thick piece of metal as a guide with a hole in it over the bolt hole and use a flat bottom drill or an end mill to flatten out an area on the broken angled bolt...possibly using a transfer punch to center punch it with and then drill as you would any other broken bolt. The flat bottom drill won"t wander off center as much with a good pilot hole guiding it. You need to get all that angle part out of there cause it"ll just keep throwing the larger drills off center. The smaller flat bottom drill don"t even have to be on center to get the angled part whittled away...but the flatter you can get the whole top of the broken bolt...the better your chances of staying on center with the drills that count will be...left handed twist drills if you got them. Fred OH

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Alan Y.

08-24-2004 03:34:03




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 Re: Stud broke on 45 degree angle, any hope? in reply to Kevin2, 08-23-2004 18:24:39  
I don't know how practical this is for you but Snap-on has small cylindrical tools called drill guides. You locate the appropriate size guide over the hole and drill down the hole in the center. Not everyone has access to a Snap-on dealer but you can also buy online at their website.



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mole

08-23-2004 21:50:01




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 Re: Stud broke on 45 degree angle, any hope? in reply to Kevin2, 08-23-2004 18:24:39  
I use a die grinder with a bit I call a burr bit. A metal bit with teeth available in many shapes and sizes. Grind stud down flat and then drill. If you use a round ball bit and center it, you don't have to center punch it. It leaves a rounded bottom in the hole.



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Mark - IN.

08-23-2004 21:07:42




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 Re: Stud broke on 45 degree angle, any hope? in reply to Kevin2, 08-23-2004 18:24:39  
I don't have a welder and probably couldn't if I did. What I've done in the past was to tilt the drill bit on an angle so that it bisects the break as though it broke off flat and I was going into it straight. I drill a dimple into it so that my bit won't walk when I slowly angle it back up so that I will eventually am drilling straight down the bolt shaft, then I go after it with an "easy out" bit. This is assuming that the bolt broke off reletively close to the surface, and not well down into the hole. I've always had success, never thrown anything away because of any broken bolt. If that don't work, welder I guess. Good luck.

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NC Wayne

08-23-2004 21:01:08




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 Re: Stud broke on 45 degree angle, any hope? in reply to Kevin2, 08-23-2004 18:24:39  
I"m assuming since you said it broke off flush that the angle is going down into the hole and it"s not sticking out at all. If it is sticking out then try what the other post suggested and weld a nut on it. Just make sure that you don"t weld the nut to the part the stud is in and not the stud. If you do this then you might as well kiss getting the stuf out goodby because it"ll mess up the threads that it"s gonna have to back out through. If it"s all the way flush and the angle is going down into the hole then that"s another matter entirely. About the only thing you can do in that case is to get a center punch and eyeball the center and punch it.Then take a fairely small bit and start it in the punch mark. Don"t worry that yor starting at an angle, just get a small hole/pocket established and slowely bring the drill around and line the bit up with the stud so your drilling straight. Go ahead and drill this pilot hole all the way through, or at least as deep as possible. Once you get that pilot hole in it"s simply a matter of stepping up to progressivly larger bits, and repeating the same procedure each time til you get the size hole you want, or til you get it drilled out far enough to peel the threads out. Just remember start the bit at the angle the stud is broken at and once it starts cutting and forms a small pocket slowely bring it around til your drilling straight. Do this and you should be alright. Hope this helps, and good luck.

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GMorrison

08-23-2004 18:44:31




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 Re: Stud broke on 45 degree angle, any hope? in reply to Kevin2, 08-23-2004 18:24:39  
The best way to deal with this sort of problem is with a wire feed welder. You can position a nut of appropriate size over the hole/stud fragment, and use the wire feed welder to weld the nut to the stud, building up weld to the nut if necessary. This does 2 things - first it gives you a way to grip and turn the stud, and second it puts concentrated heat into the stud, helping to break it loose. I have used this method over and over on all sorts of broken studs, bolts etc in iron, steel, and even aluminum.

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