Using a Tig to remove a broken rusted in bolt

[Comanche Scott]

This weeks welding tip video is on removing a broken bolt, with a broken easy-out stuck in it, from an exhaust manifold. He's using tig, and explains his choice of filler rod.
Man, who hasn't been here before... ......
This guy is my hero!

Thought you might enjoy.

Welding tip video

[specfour]

Good tip, I havedone the old weld a nut or an old socket trick many times with a stick or mig welder. I guess one of these days I am going to have to learn to tig. Thanks for posting it!!

Andy

[R290]

I saw that he used 309, I use 312 stainless. 312 has a higher tensile strength. One other tip I do is put a washer over the broken stud. This provides some protection from the welder and give me a nice base for the nut. I have not done an exhaust stud, but have removed several from axle housings/knuckles
Plus I'm using an arc welder. So even when the stud is broken down inside the hole the flux from the 312 rod floats to the outside and prevents you from welding the stud to the casting. I had a cool vid on youtube, until my son deleted it from his acct.
So I thought I would point out you don't have to have a TIG welder to do this.

http://www.amazon.com/Forney-44556-S.../dp/B000TG9ZHY

[67lemans]

Ahh yes the ol welder to remove broken bolt trick. Here are a few tips that may help those who do not have a welder
If you break a drill bit or EZ out off in a bolt. Grab a center punch and hammer and pound away. You will find that the bits are brittle and you may be able to break small chunks off.
You can also try a mixture of alum and water. This will slowly eat away and the steel and may loosen it enough to be removed with pliers or something.
My secret weapon when removing a broken bolt is a carbide bur bit and a dental bit and dremel.
Use the small carbide bit to make the fastener even (as you cant really center drill a bolt that isnt even) and then use the dental bit (same as a dentist uses) to punch through it forms a perfect centered pilot hole. Done this plenty of times on stainless and titanium bolts.