ok i broke the exaust stud on my bayou i broke it right befor the threads end i need advice on how to get it out iv broke them on my ttr 90 and iv drilled it out and taped them but i dont want to do that any ideas
Got a problem need help
- Thread starter mud runner
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Got a welder? The neatest and easiest trick I know to get the broken stud out is to MiG weld a nut to the protruding end of the stud and carefully wrench it out. Pick yourself a good, usable nut (1/4 and 5/15" ones work great) that you can grip with a wrench. Slip the nut over the stud, or at least get it over top of the broken piece.
Fill the inside of the nut up with a nice hot bead of weld, and let it cool for a few mins. Then take your wrench and carefully unscrew the nut, with the stud attached. More than one attempt may be required if you didn't get a good weld penetration the first time, but be patient and you'll usually get it out. Ive even used this trick to extract broken pieces of bolts held in by Loctite and rust...
Fill the inside of the nut up with a nice hot bead of weld, and let it cool for a few mins. Then take your wrench and carefully unscrew the nut, with the stud attached. More than one attempt may be required if you didn't get a good weld penetration the first time, but be patient and you'll usually get it out. Ive even used this trick to extract broken pieces of bolts held in by Loctite and rust...
the problwm with that is i have a welder at my house but im about 100 miles away from my house at my grandparents and my grandmas nieces husband has one bue he is out of wire and im running low on cash because iv had to spend some money on it synce iv been up here but if i can find some wire cheap ill get it because iv got to weld my exaust and the mounts that hold my front bumper because it looks like a tree jumped out in front of the person that owned it befor me and just about broke two mounts off
Hopefully you can get it out this way...drilling should be a last resort IMO. Ive drilled plenty of bolts out, and my success rate is about 40% if done by hand, and MAYBE 50% if done with a drill press. Its just too easy to go in off-center or at an angle with a drill bit. Plus, even if you can drill a nice, centered hole, you still either have to remove the remainder of the broken bolt with an EZ out, or by drilling the hole oversize and repairing the threads with a Helicoil insert.
I hate EZ outs...especially the small ones...as they are inherently brittle and will break faster than a dead pine branch in a wind storm if you apply too much torque. And as anyone who has snapped off an EZ out can tell you, once it goes -tink-, its all over. Short of a carbide drill bit, that broken EZ out butt is not coming out. Helicoils, on the other hand, work great.... If you have the right size one, have a clean, round, properly-tapped hole to put it in, and know how to install it. You see where Im going with this...
Don't drill unless you have to.
I hate EZ outs...especially the small ones...as they are inherently brittle and will break faster than a dead pine branch in a wind storm if you apply too much torque. And as anyone who has snapped off an EZ out can tell you, once it goes -tink-, its all over. Short of a carbide drill bit, that broken EZ out butt is not coming out. Helicoils, on the other hand, work great.... If you have the right size one, have a clean, round, properly-tapped hole to put it in, and know how to install it. You see where Im going with this...
Don't drill unless you have to.
Here's a quick vid (not mine) to demonstrate the technique Im talking about.
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i know exactly what you are talking about all ex outs suck imo becaust they breal so easly especaly the cheap ones but even the good ones break easy
Use the biggest ez out you can, and heat around the bolt with a torch. Heat makes a big difference when something is stuck. You're heating aluminum, so be careful not to get it too hot.
