remove broken 10mm cylinder head bolt with 5mm sticking up

[cocker]

How about an Irwin nut and stud removal set? I have found them quite good.

I've had very little success with any of these things

 

[the snooper]

How about an Irwin nut and stud removal set? I have found them quite good.

only problem would be no heat with that method

 

[Woody.v8]

only problem would be no heat with that method

And nowt to grip! OP says 5mm protruding, I tell you what if the OP was closer i would have done it by now without all this conflab! (no offence Snoop, just couldn't be bothered to make a separate post)

 

[rusty weld]

only problem would be no heat with that method

In this instance, 5mm is not a lot to bite on!

 

[the snooper]

And nowt to grip! OP says 5mm protruding, I tell you what if the OP was closer i would have done it by now without all this conflab! (no offence Snoop, just couldn't be bothered to make a separate post)

having the right tools makes every thing easy

 

[Woody.v8]

having the right tools makes every thing easy

Too true, We get spoilt as we get better equipped!

 

[the snooper]

Too true, We get spoilt as we get better equipped!

without a doubt, how did we ever manage n the past

 

[roofman]

Iff the OP is northwest (Chester) region ile sort it for him not a problem or at the very least have a go

 

[the snooper]

Iff the OP is northwest (Chester) region ile sort it for him not a problem or at the very least have a go

Longbridge/Birmingham

 

[roofman]

Longbridge/Birmingham

Oh well its mole grips time then unless anyone else wants to try help...hate seeing guys struggling for solutions as ive been there myself

 

[I'm getting on a bit]

I'll go with the crowd on this weld a nut on get it glowing. It would help a heck of a lot if you put a specific location on your profile rather than uk. This will encourage the experienced and helpful members on your door step to offer you the use of there welders and help you get the thing out. If your near the Royston cambs area Id gladly help you out.
Now to the minority that says this won't work. Yes I agree the welded nut won't be as strong as the original that snapped but it doesn't need to be in fact once it's hot that heat will quickly disapate down the bolt shaft. Yes 75 mm with out issue. The bolt will expand and crack that stubborn rust seal. The Alu head will suck the heat away from the bolt also and also expand a little. The expansion of the heated parts is what makes this work and a lot less force is required to crack it loose. I've done this before on snapped studs and in most cases they move pretty easy.

You raise some interesting points and you are someone I respect for your tig knowledge.

But no disrespect you agree that a welded nut would not match the strength of the stud, but he broke the stud trying to remove it so the nut will fail.

Now you rightly say that heat helps, but not a what 1 to 2 second burst, but not to a depth of 75mm as you say surrounded by heat sucking aluminium.

Now when I suggested that even continuall heating has failed for me a comedian said this was wrong.

But the reason it failed was because the casting was sucking the heat away.

But it could work in this case due to the nature of the casting as it looks in the picture.

At the end of the day I am only trying to help the op get his problem solved not trying to contradict just for the sake of it.

I've been wrong in the past, I thought I was wrong but I wasnt.

 

[ajlelectronics]

I've been wrong in the past, I thought I was wrong but I wasnt.

You can't have asked a woman, because you would have been left in no doubt that you were still wrong!

 

[MattH]

Plenty of people have had success welding a nut on, myself included.
You say you have heated with a torch. I would suggest (respectfully) that you try the weld method yourself before dismissing it.

 

[Woody.v8]

You raise some interesting points and you are someone I respect for your tig knowledge.

But no disrespect you agree that a welded nut would not match the strength of the stud, but he broke the stud trying to remove it so the nut will fail.

Now you rightly say that heat helps, but not a what 1 to 2 second burst, but not to a depth of 75mm as you say surrounded by heat sucking aluminium.

Now when I suggested that even continuall heating has failed for me a comedian said this was wrong.

But the reason it failed was because the casting was sucking the heat away.

But it could work in this case due to the nature of the casting as it looks in the picture.

At the end of the day I am only trying to help the op get his problem solved not trying to contradict just for the sake of it.

I've been wrong in the past, I thought I was wrong but I wasnt.

This is why i said initially that i would use impact to remove said stud after welding, the shock moves what torsion wouldn't.

 

[the snooper]

Now you rightly say that heat helps, but not a what 1 to 2 second burst, but not to a depth of 75mm as you say surrounded by heat sucking aluminium.

the thing is it does work and has been used by plenty of us on here, and has worked when heating the external of the component has failed

 

[normspanners]

No welded on nut is ever going to be as strong as the original stud

. Not wishing to disagree but I have welded hundreds of nuts onto sheared bolts brake pipe fittings etc etc and have sheared the stud again further down so the welding method CAN be just as strong at joining the nut to the stud.
If the stud left is 65mm long,it will be stuck in the block not the thread IMO, it will be the plain part of the bolt that has expanded with rust and locked into the plain part of the block so heat is the only way to free it by expanding and contracting the bolt to free the rust, again this is IMO.

 

[rusty weld]

the thing is it does work and has been used by plenty of us on here, and has worked when heating the external of the component has failed

I wonder if it works because the oxide layer between stud and componant form a partial insulating layer? Any thoughts?

 

[I'm getting on a bit]

This is why i said initially that i would use impact to remove said stud after welding, the shock moves what torsion wouldn't.

My first post on this thread said use impact driver

 

[the snooper]

I wonder if it works because the oxide layer between stud and componant form a partial insulating layer? Any thoughts?

not to sure on the chemistry of it, it could be that the expanding bolt compacts the rust slightly leaving space for it to move

 

[Richard.]

You raise some interesting points and you are someone I respect for your tig knowledge.

But no disrespect you agree that a welded nut would not match the strength of the stud, but he broke the stud trying to remove it so the nut will fail.

Now you rightly say that heat helps, but not a what 1 to 2 second burst, but not to a depth of 75mm as you say surrounded by heat sucking aluminium.

Now when I suggested that even continuall heating has failed for me a comedian said this was wrong.

But the reason it failed was because the casting was sucking the heat away.

But it could work in this case due to the nature of the casting as it looks in the picture.

At the end of the day I am only trying to help the op get his problem solved not trying to contradict just for the sake of it.

I've been wrong in the past, I thought I was wrong but I wasnt.

Cheers and likewise I respect a lot of your knowledgeable posts too.
It is something that works or has at least for me on a number of occasions I would not advise it if I hadn't had success . Your dead right the Alu will suck the heat out of the bolt but remember the Alu is a great heat conducting material so although it removes the heat it also holds it very well too and this again Aids to the release of the seized part . Yes the strength of the bolt is completely compromised by the heat of welding but the expansion of the heated items means it dose not need the strength any more to be cracked loose. It's not 100% guaranteed but looking at the job it's the best chance IMO. We'll have to agree to disagree I'm afraid but I suppose it's the debate and different views that makes these threads interesting.