HELP Head stud broke off inside block.

kazin1111 · 09-29-2008, 05:34 AM

Without leaving explitives.... My head stud snapped off when I was tightening it. It is stuck inside the block and I cant fish it out with a screwdriver.... I can't get it to turn. HELP!!!!

Gairloch · 09-29-2008, 05:49 AM

Are you talking about an exhaust stud or what?

Is the metal of the stud broken off inside the head or is it sticking out at all?

If it's broken off inside then you're stuck having to drill it out. You're going to have to be damn careful because the stud is steel and the head is aluminum.

Mista 2 · 09-29-2008, 07:31 AM

Do you have any ezi outs? aka screw extractors?

kazin1111 · 09-29-2008, 08:52 AM

no I don't, but i'll figure out what those are. it is a head stud for torquing down the head to the block. what do I do... Drill? please tell me there is an alternative... it isn't sticking out at all. its completely snapped in the block.

romz · 09-29-2008, 09:37 AM

Quote:

Originally Posted by kazin1111

no I don't, but i'll figure out what those are. it is a head stud for torquing down the head to the block. what do I do... Drill? please tell me there is an alternative... it isn't sticking out at all. its completely snapped in the block.

Mate,

Ezy-outs are one of the best things i've bought.

i would imagine the bolt has sheared flush with the block. just drill a small 2-3mm pilot-hole in the top of the bolt stub still stuck in the block (this is the hardest part, as the sheared surface is seldom flat, and you have to be VERY careful that the drill bit doesnt wander and touch the alloy. just take it SLOW)

then it always helps to put a bit of Supa-Grip (or some other friction enhancer if you have one at hand...also another great purchase) into the hole and slowly wind the Easy-out in. It has a reverse thread so as wou wind it in, as it starts to bite it winds the sheared bolt out.

Good luck with it mate

Roadflare16 · 09-29-2008, 09:39 AM

an EZ OUT is what you're looking for, it's simply a drill bit that's designed to snag in the opposite direction. I know that doesn't make much sense. You drill a small hole in the middle of that broken stud, jam this easy out in there, and as you "lefty-loosy" it, the bit is designed to dig in further the more you try to loosen that stud. May wanna wd-40 that s*** first though cuz if it was stuck enough to break, I'm sure it won't be all that EZ to get out :/

PVpower · 09-29-2008, 02:51 PM

There is this stuff like wd-40 i cant remember the name but i use it all the time to clean out studs and what not. i found it at any local part store.

Gairloch · 09-29-2008, 07:34 PM

Have you had any success using EZ outs on something that small?

miracleman89 · 09-29-2008, 07:56 PM

I need to get some of these ezy-outs! I had some of those bolts break off when removing the plastic panels on the bottom of my deuce!

jholder · 09-29-2008, 08:53 PM

this situation is "the suck".

+13 for screw extractor. You'd need to look up the directions to be sure, but iirc you drill the pilot hole as mentioned (you need it big enough to get the tip of the extractor into it enough to bite), then tap it with a mallet to get it seated, and then back the screw out.

As a side question to you other users, what do you use to attach to the other side of the ez out? Mine have square heads, and when my drill wont get them out im slightly screwed.

kazin1111 · 09-30-2008, 02:54 PM

Looks like I completely failed at this. The bolt is still buried 1 inch deep into the block and I have ovaled out the hole. I towed it to a shop and they said get a new block. I called 2 machine shops and they said get a new block...

CyFi · 09-30-2008, 04:37 PM

Thats unfortunate, keep calling machine shops, they have experience with this kind of stuff. Chances are it snapped because the threads were locked by something like corrosion, no way an easy out is going to get enough torque on that. Only thing i can thnk of is try heating the surrounding metal and try to easyout it, but it sounds like a job for a machine shop thats willing to do it.

rwdkid · 09-30-2008, 06:46 PM

Quote:

Originally Posted by PVpower

There is this stuff like wd-40 i cant remember the name but i use it all the time to clean out studs and what not. i found it at any local part store.

Could it be PB Penetrating oil?

miracleman89 · 09-30-2008, 09:47 PM

Good ol' PB lube!!! I swear by that stuff! Works great!!!!

jholder · 09-30-2008, 11:35 PM

Quote:

Originally Posted by miracleman89

Good ol' PB lube!!! I swear by that stuff! Works great!!!!

Thats what she said... OHHHHHH!

*cricket* *cricket*

tjmr2 · 10-07-2008, 11:13 PM

EZ outs are made to be twisted with tap handles which are special adjustable handles made to apply an even force to a tap. The EZ out is really hard steel, harder than high speed steel drill bits. Break an EZ out off in a broken bolt and about all that will drill it out is a carbide drill.

There are specific size drill bits for each size of EZ out, sometimes it is listed on the EZ out itself.

There are also other options for Kazin than replacing the block. Sadly a machine shop won't be able to set up to remove the broken head stud with the block in the car. Probably have to strip the block so they can bolt it down on a mill to drill it out accurately. They might be able to use a bigger EZ out. Or in a last resort drill out the stud and install a helicoil or a threaded insert.

A friend once told me of a bolt that he had broken off in a block, he called a welder that somehow welded a stud to the broken off bolt, which he then unscrewed.

There are many options other than replacing the block. Ask the old machinist or welder, how to get that bad boy out. Try the instructors at the local community college.

Good luck!

kazin1111 · 10-07-2008, 11:39 PM

heh... thanks tjmr2. But ive tried about 16 shops now, towed it 4 times... i'm going for the hail mary. JB weld. I'm gonna seal that bolt hole and put back on the head...

mr220v · 10-08-2008, 01:07 PM

I'd try the 16v block first.....or possibly just getting a different silvertop and parting this one out. You could get a good bit of your money back this way. Probably $300 for the head and itbs, and I'd give you $50 for the cut harness.

If you can get a replacement for $500, that would be the way to go.

kazin1111 · 10-09-2008, 01:45 AM

Wont sell me just a replacement. has to be entire swap, 1200 is the cheapest so far. Jb weld seems to be holding, 2 busted bolts now. I just figured out my father in laws torque wrench is fautly. Could be why i'm in this whole mess... anways. sealed both bolts, compression was good on 3, 30 lower on the other. I had to cut my timing belt cover last week while I was installing a replacement tensioner. I aparently didn't do a good job on it because my timing belt just got eaten up and snapped... so now I"m pulling the motor out. I get married tomorrow so I guess this has to sit for a couple weeks. any tricks to raising compression on 1 cyl? Even something that could damage the motor? I'm not exactly worried about trashing this motor. after the jb weld job I did on it, I don't think I will be able to sell it.

toy-driver · 10-11-2008, 12:31 AM

Oh my goodness.....

09-29-2008, 05:34 AM	#1 (permalink)
kazin1111 Weak Skills Join Date: Feb 2008 Posts: 103 Thanks: 11 Thanked 0 Times in 0 Posts iTrader Rating: (0/0% )	HELP Head stud broke off inside block. Without leaving explitives.... My head stud snapped off when I was tightening it. It is stuck inside the block and I cant fish it out with a screwdriver.... I can't get it to turn. HELP!!!!

09-29-2008, 05:49 AM	#2 (permalink)
Gairloch Dreaming of apexes Join Date: Aug 2005 Location: Minneapolis, MN Posts: 4,426 Thanks: 114 Thanked 219 Times in 192 Posts My Google Map iTrader Rating: (7/100% )	Are you talking about an exhaust stud or what? Is the metal of the stud broken off inside the head or is it sticking out at all? If it's broken off inside then you're stuck having to drill it out. You're going to have to be damn careful because the stud is steel and the head is aluminum. __________________ "Inside the car, the world beyond the driver's immediate horizon ceases to exist. Alone with the solitude of his desire, survival sense numbed by the speed, he's outrun the mediocrity of the outside world, slipped the shackles it tries to clamp on us all. He is running free, chased only by a fear of failure, for failure is to risk ejection into the real world." ~Mark Hughes

09-29-2008, 07:31 AM	#3 (permalink)
Mista 2 Cage Fighter Join Date: Nov 2006 Location: Adelaide, Australia Posts: 457 Thanks: 16 Thanked 21 Times in 21 Posts My Google Map iTrader Rating: (0/0% )	Do you have any ezi outs? aka screw extractors?

09-29-2008, 08:52 AM	#4 (permalink)
kazin1111 Weak Skills Join Date: Feb 2008 Posts: 103 Thanks: 11 Thanked 0 Times in 0 Posts iTrader Rating: (0/0% )	no I don't, but i'll figure out what those are. it is a head stud for torquing down the head to the block. what do I do... Drill? please tell me there is an alternative... it isn't sticking out at all. its completely snapped in the block.

09-29-2008, 09:39 AM	#6 (permalink)
Roadflare16 No Skills Join Date: Sep 2008 Posts: 3 Thanks: 0 Thanked 0 Times in 0 Posts iTrader Rating: (0/0% )	an EZ OUT is what you're looking for, it's simply a drill bit that's designed to snag in the opposite direction. I know that doesn't make much sense. You drill a small hole in the middle of that broken stud, jam this easy out in there, and as you "lefty-loosy" it, the bit is designed to dig in further the more you try to loosen that stud. May wanna wd-40 that s*** first though cuz if it was stuck enough to break, I'm sure it won't be all that EZ to get out :/

09-29-2008, 02:51 PM	#7 (permalink)
PVpower Some Skills Join Date: Feb 2008 Posts: 99 Thanks: 0 Thanked 0 Times in 0 Posts My Google Map iTrader Rating: (0/0% )	There is this stuff like wd-40 i cant remember the name but i use it all the time to clean out studs and what not. i found it at any local part store.

09-29-2008, 07:34 PM	#8 (permalink)
Gairloch Dreaming of apexes Join Date: Aug 2005 Location: Minneapolis, MN Posts: 4,426 Thanks: 114 Thanked 219 Times in 192 Posts My Google Map iTrader Rating: (7/100% )	Have you had any success using EZ outs on something that small?

09-29-2008, 07:56 PM	#9 (permalink)
miracleman89 MR2 under construction! Join Date: Mar 2008 Location: Morenci, AZ Posts: 254 Thanks: 11 Thanked 3 Times in 3 Posts iTrader Rating: (0/0% )	I need to get some of these ezy-outs! I had some of those bolts break off when removing the plastic panels on the bottom of my deuce!

09-29-2008, 08:53 PM	#10 (permalink)
jholder I put the ho in 'hosale Join Date: Nov 2007 Location: Huntsville, AL Posts: 195 Thanks: 5 Thanked 9 Times in 6 Posts iTrader Rating: (1/100% )	this situation is "the suck". +13 for screw extractor. You'd need to look up the directions to be sure, but iirc you drill the pilot hole as mentioned (you need it big enough to get the tip of the extractor into it enough to bite), then tap it with a mallet to get it seated, and then back the screw out. As a side question to you other users, what do you use to attach to the other side of the ez out? Mine have square heads, and when my drill wont get them out im slightly screwed.

09-30-2008, 02:54 PM	#11 (permalink)
kazin1111 Weak Skills Join Date: Feb 2008 Posts: 103 Thanks: 11 Thanked 0 Times in 0 Posts iTrader Rating: (0/0% )	Looks like I completely failed at this. The bolt is still buried 1 inch deep into the block and I have ovaled out the hole. I towed it to a shop and they said get a new block. I called 2 machine shops and they said get a new block...

09-30-2008, 04:37 PM	#12 (permalink)
CyFi Hypnotize minds! Join Date: Oct 2005 Posts: 1,360 Thanks: 12 Thanked 36 Times in 34 Posts iTrader Rating: (10/100% )	Thats unfortunate, keep calling machine shops, they have experience with this kind of stuff. Chances are it snapped because the threads were locked by something like corrosion, no way an easy out is going to get enough torque on that. Only thing i can thnk of is try heating the surrounding metal and try to easyout it, but it sounds like a job for a machine shop thats willing to do it.

09-30-2008, 09:47 PM	#14 (permalink)
miracleman89 MR2 under construction! Join Date: Mar 2008 Location: Morenci, AZ Posts: 254 Thanks: 11 Thanked 3 Times in 3 Posts iTrader Rating: (0/0% )	Good ol' PB lube!!! I swear by that stuff! Works great!!!!

10-07-2008, 11:13 PM	#16 (permalink)
tjmr2 Cage Fighter Join Date: Jan 2008 Location: Colorado Posts: 162 Thanks: 0 Thanked 29 Times in 27 Posts My Google Map iTrader Rating: (0/0% )	EZ outs are made to be twisted with tap handles which are special adjustable handles made to apply an even force to a tap. The EZ out is really hard steel, harder than high speed steel drill bits. Break an EZ out off in a broken bolt and about all that will drill it out is a carbide drill. There are specific size drill bits for each size of EZ out, sometimes it is listed on the EZ out itself. There are also other options for Kazin than replacing the block. Sadly a machine shop won't be able to set up to remove the broken head stud with the block in the car. Probably have to strip the block so they can bolt it down on a mill to drill it out accurately. They might be able to use a bigger EZ out. Or in a last resort drill out the stud and install a helicoil or a threaded insert. A friend once told me of a bolt that he had broken off in a block, he called a welder that somehow welded a stud to the broken off bolt, which he then unscrewed. There are many options other than replacing the block. Ask the old machinist or welder, how to get that bad boy out. Try the instructors at the local community college. Good luck!

10-07-2008, 11:39 PM	#17 (permalink)
kazin1111 Weak Skills Join Date: Feb 2008 Posts: 103 Thanks: 11 Thanked 0 Times in 0 Posts iTrader Rating: (0/0% )	heh... thanks tjmr2. But ive tried about 16 shops now, towed it 4 times... i'm going for the hail mary. JB weld. I'm gonna seal that bolt hole and put back on the head...

10-08-2008, 01:07 PM	#18 (permalink)
mr220v Beams Owners Group Join Date: Mar 2006 Posts: 1,255 Thanks: 13 Thanked 90 Times in 76 Posts iTrader Rating: (7/100% )	I'd try the 16v block first.....or possibly just getting a different silvertop and parting this one out. You could get a good bit of your money back this way. Probably $300 for the head and itbs, and I'd give you $50 for the cut harness. If you can get a replacement for $500, that would be the way to go.

10-09-2008, 01:45 AM	#19 (permalink)
kazin1111 Weak Skills Join Date: Feb 2008 Posts: 103 Thanks: 11 Thanked 0 Times in 0 Posts iTrader Rating: (0/0% )	Wont sell me just a replacement. has to be entire swap, 1200 is the cheapest so far. Jb weld seems to be holding, 2 busted bolts now. I just figured out my father in laws torque wrench is fautly. Could be why i'm in this whole mess... anways. sealed both bolts, compression was good on 3, 30 lower on the other. I had to cut my timing belt cover last week while I was installing a replacement tensioner. I aparently didn't do a good job on it because my timing belt just got eaten up and snapped... so now I"m pulling the motor out. I get married tomorrow so I guess this has to sit for a couple weeks. any tricks to raising compression on 1 cyl? Even something that could damage the motor? I'm not exactly worried about trashing this motor. after the jb weld job I did on it, I don't think I will be able to sell it.

10-11-2008, 12:31 AM	#20 (permalink)
toy-driver _________________ Join Date: Oct 2007 Location: Dallas, TX Posts: 186 Thanks: 1 Thanked 8 Times in 8 Posts iTrader Rating: (1/100% )	Oh my goodness.....