Any old Indian tricks for removing broken studs from aluminum engine head?

Vernon · 2007-05-13T17:16:44+00:00

We just acquired a VW diesel rabbit for $400. The intake manifoldfell off after all four of its mounting bolts broke.One of these broke off sufficiently above the machined side of thehead that we were able to turn it out by striking the burr with achisel.However, the other three are broken slightly beneath the surface.Ideally, we'd like to remove these without having to remove theIndian .. er.. engine...I am wondering about the possibility of striking an arc on the end ofeach bolt and building this up until it's above the surface and thenturning 'em out with a chisel as we did the first one.Some time ago I read about a trick like this where the guy strick thearc inside a small piece of copper tubing placed into the hole.However, I presume that in his case he was working with a steel boltinside a steel head and that the purpose of the copper tubing was tokeep from welding the stud to the head.So the plan is to use some reasonably small rod at a suitably lowamperage WITHOUT the copper tubing. As I perceive things the aluminumwill not melt because it is a better conductor of heat than the steel.However, in my mind everything is easy. It's at the "realityinterface" that things start to go wrong.So, is this a viable plan? And if so, what rod flavor and diameterwould YOU recommend.All answers appreciated. Correct answers REALLY appreciated. Plan"b" is to remove the engine and drill 'em out.There is just enough room between the work area and the firewall tomake this doable if I bend the rod into an "L" shape.Thanks!Vernon

May 13, 2007 27 Replies

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brian458666 19 years ago

To return to this topic, first- there are 6 bolts on the intake (and 8 studs for the exhaust) I think I've remembered why welding to the broken exhaust studs didn't ring any bells for me... every time I've seen it tried, the alloys used for the studs became so fragile that the problem became magnified and required grinding past the crystallized bit. And I remind you that while I have a machine, I'm not a welder. I can stick things together but if I need something properly welded it goes to the welder down the street. Brian

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Vernon 19 years ago

Just when I thought I had mined all the gold outta this vein I stumble back and find more!

Thank you, one and all! I especially thank you Wayne, for the tip about stainless! You're a fine guy even though you won't admit you live in Huntsville .

Vernon

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Wayne Cook 19 years ago

You're welcome. I would of chimed in earlier but I'm not sure which way I'm going at the moment. Between moving my wife into a trailer next door (from the nursing home), a very busy mower season, and my best hand quitting me right in the middle of it all I've been more than a little stressed.

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Jimmie D 19 years ago

I have broken some but not in a long time. I figured that since he got one out so easy the other probably werent that tight either. Just seemd like thy are hell bent on using a welder to do this, not my first choice.

Jimmie

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Wayne Cook 19 years ago

When you've spent three hours to remove 5 broken drill bits and a EZ out on a job that would of taken 5 minutes with a welder you'll understand why. Welding is my first choice and EZ outs are way down the list of options. I see way to many messes where people who first use the wrong kind of EZ out (the spiral type should be illegal to make) and don't know how to properly use one in the first place. They usually come to me after they've made the mess. It would be cheaper to bring it to me in the first place.

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RoyJ 19 years ago

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John 19 years ago

I have found that the welded bolt method works the best if you can't get at the stud. The other method I use is to drill the stud and then us a left handed tap on it. Then insert a left handed stud or bolt and turn it out. If the bolt snaps off you can still step drill the bolt up to near the minor diameter of the thread and just pick it out with a sharp pick.

The main thing is not to stick an easyout in it and snap it off. It isn't easy after that unless you have a tap burner or edm machine.

John

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