Thread: 20V MK1 Engine Swap HELP Head stud broke off inside block.
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Old 10-07-2008, 11:13 PM   #16 (permalink)
tjmr2
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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!
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