broken stud with an broken ez out in it

what rocky says is the right way big thing is getting plating off and good hot weld

 

That bolt with a hole drilled in it would make a nice guide for drilling the bolt out.

 

Having worked in fab shops as a machinist, i love the argueing on this thread, it's typical welder vs machinist debate, Because you can pretty much get anything done or made through welding or machining but everyone has their way of doing it

 

Another piece of advise for anyone who reads this take your square "easy outs" and throw them in the fucking scrap bin because scrap weight is their best use and then buy a set of this style bolt extractors



These are nice because they will start to twist before they break giving you a chance to quit and drill out to the next larger size ore use another method. They are pretty tough but not having a broken extractor inside of your broken bolt is key.

 

Stud extractor shown works like a top. I've used it with an old Lincoln crackerbox welder and it does what they say it will do. Won't stick to the threads, just put it down the hole through a nut and weld out. Welds through the end of the rod only. Had to get them from a welding supply place though.

 

No actually you didn't, not even close.

 

I think this is where we are.Some just don't understand how simple it is.Welding is so easy.

 

Have used a plasma cutter for this situation. use short blast, and be careful of the stuff coming out , it gets on ya somehow .

 

EZ outs have their uses but the user has to realize how much pressure they can take before breaking and that pressure needs to be applied evenly. As has been said, if the bolt broke off from trying to turn it out, something has to be done to loosen it before using an EZ out. I like to drill through the bolt so penetrant can be applied from both ends. When using a penetrant you have to be patient as it takes time to work. If a torch is available, heat the bolt after the hole is drilled and allow it to cool before inserting the EZ out. Using an EZ out in a hot bolt ruins the heat treating of the EZ Out and makes it brittle.

If you break an EZ out or a tap, remember they are made of hardened steel. It was hardened by heat treating and can be softened by heat treating. Use a welding tip and heat the bolt and EZ out to a cherry red. Slowly move the torch away so the steel cools slowly. Cooling steel quickly makes it harder. Allowing it to cool slowly anneals (softens) it. Once it cools, it can be drilled. A die grinder with a ball carbide burr is handy to make a good surface to start drilling from.

Welding to a broken bolt works well but you need a steady hand, a knowledge of welding and experience is always a plus.

 

Looks like it's in post #2 which was the first response.

 

I did the same thing with a flat head studs on the heads. It broke off almost flush and made it worse by snapping off an easy out. Shop had to remove the easy out tip. Then they welded a bolt to the stud. Lots of Kroil and heat and it was out. Cost about $40 and the block was brought to them for a few days.

 

Google rescue bit. Pretty amazing.

 

If you do manage to get the piece of the easy out out, you can get the stud out by drilling all the way through it, then use a torch and cut the rest of it out. You have to be pretty steady and cut from the inside of the hole you drilled out to the threads. If you do it right, you won't mess up the threads. You may need to run a tap through them to clean it up.

 

Another one who didn't bother reading it. If you look it contains a whole lot more technical explanation on the theory behind why it works along with some practical based experience with different situations.

 

I like this one: