HOW TO REMOVE SNAPPED STUDS / BOLTS WITH A WELDER

Summary

In this video, the creator demonstrates how to remove a snapped-off stud from a turbo housing using welding techniques. Rather than drilling out the stud, they build up the weld on the stud, allowing for easy removal without damaging the original threads. The process is explained step-by-step, emphasizing patience and care during the welding process, especially when working with different materials like aluminum. Although the example presented wasn't perfect, the technique shows an effective way to tackle stubborn snapped-off studs in automotive repair.

Takeaways

• 🔧 Snapped-off studs in car components, like turbo housings, are a common problem for mechanics.
• 🛠 The traditional method of drilling out a snapped stud and re-tapping threads is tricky and can damage original threads.
• 🔥 Welding a nut onto the end of the snapped stud is an easier and safer alternative.
• ⚠️ Care must be taken when welding studs in aluminum or sand-cast steel to avoid fusing the stud to the surrounding material.
• 🔩 Build up the stud with weld to a sufficient height so a nut can be threaded on.
• 😷 When welding coated nuts, always wear a respirator and work in a ventilated space.
• 🌡 Allow the weld to cool naturally and do not quench it, as rapid cooling can make the weld brittle.
• 🔧 Tighten a nut onto the welded stud to remove it without damaging the original threads.
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• ⏱ Patience is important when building up the weld, especially if the stud is slightly below the surface or previously damaged.
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• 📝 After removal, threads may require cleaning or tapping to restore them fully.
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• 💡 This method works even on studs that have been previously botched or cross-threaded.

Q & A

What is the main issue being addressed in this video?

The video addresses how to remove a snapped-off stud from a turbo housing without damaging the original threads.

What is one of the common options for removing snapped-off studs, and why is it challenging?

One option is to drill out the stud and then re-tap the threads, but this is tricky because it risks damaging the original threads.

What is the preferred method demonstrated in the video for removing a snapped stud?

The preferred method is welding a nut onto the end of the snapped stud, which can then be unscrewed without damaging the surrounding threads.

What precautions should be taken when welding a stud onto a turbo housing?

You should ensure that the welding is done directly onto the stud, not just filling the nut with weld. Also, be careful not to weld the stud to the material surrounding it (such as aluminum), as this could make removal difficult.

Why is it important not to cool the welded stud quickly after welding?

Cooling the weld quickly (e.g., by quenching it) can make the weld brittle, increasing the chances of it breaking when you attempt to undo it.

What safety gear is recommended when welding a coated nut?

A respirator should be worn, and the welding should be done in a well-ventilated space to avoid inhaling fumes from the coated nut.

What happens if the stud is snapped off flush with the surface?

If the stud is snapped off flush with the surface, the technician would need to build the weld up to a sufficient height and then attach the nut to it for easy removal.

What should you do if the stud is broken off slightly below the surface?

If the stud is broken off slightly below the surface, you should carefully build the weld up on top of the stud, ensuring it does not fuse with the surrounding material.

What does the video suggest you do if the thread is damaged while removing the stud?

If the threads are damaged, the video suggests running a tap through the threads to restore them.

Was the stud removal in the video a perfect example of the process?

No, the video acknowledges that the removal process in the example wasn't ideal, as it was a tricky case with pre-existing damage to the threads. The presenter mentions that the first attempt, which wasn't filmed, went much more smoothly.