Hey there,

I've got a broken stud in the engine block. It's at the back where the bellhousing bolts on. Fortunately, the engine is out of the car so it's easy access. But a couple of hours a day for the last couple of days with the 5/32 drill bit has gotten a hole maybe a 1/16" deep. I'm thinking the better way is weld on a washer, then a nut, and turn it out.

Got a good washer (thick fender washer with hole just slight smaller than stud size) and a decent nut. Only problem is...I don't own a welder, nor do I know how to weld.

Any help/suggestions here? Anyone want to make some gas money?

TIA,
Marq

Get a new drill bit that will drill the bolt and than go to the next size up until it comes loose.

Start the pilot hole with a smaller bit, 1/16 or so and work up from there. Go slow and dont break the bit. You'll be fine.

I thought about continuing the drilling saga...

But instead of spending HOURS in the garage fixing something I screwed up (when I'd rather be spending that time with my 4- and 2-year old daughters), I called up a welder locally to weld on a washer to the remainder of the stud.

He shows up at 1:00 pm. Badda bing, badda boom!
The stud is out by 1:30 pm.

Wouldn't do it any other way ever again. (Don't ask what it cost me, but the girls will only be little once - and it's over much too fast.)


pics follow...

Pic above is after 4 hours of slow drilling (and 3 bits and plenty of cutting oil.)

Pic below is stud removed after the washer was welded on. Undoubtedly, the heat from the weld helped loosen the stud in the block. We didn't even have to weld a nut to get a satisfactory purchase on the washer. Vise clamps did the trick.

Good as new.

Now to make sure my torque wrench is properly calibrated. The "click" is not as noticeable as it once was...

If you've got a welder and a modicum of skills, this was the way to do it, no question. WAY easier!

Be careful bolting the bell housing back on. It may crack since the surface is uneven.

I've seen a few blocks with that off-machined area, may be factory. That bolt looks like it may have been on the long side, don't it?