title says it all. i have 3 studs broke off (removed one with easy out) tried to get the other and snapped it. its almost flesh with the head so i cant use a weld method. any ideas how to remove them without taking it to a machine shop?

When I broke off an easy-out in a sway bar bolt once, I used the Dremel with a carbide bit to grind a divot in it, then drilled it out. You probably don't want to drill the bolt threads out of your cylinder head. But you can at least make another hole to put in another not-so-easy-out.

Or you could say "**** it", drill the thing out, and install a thread-sert.

If the part that the stud is sitting in has enough meat to it, in the past I have taken a dremel with a cutting disk and slotted the top of the stud big enough to get a large flat head screwdriver on it. The screwdriver to use would be one with a square shaft so a wrench could be used on it.Also use lots of PB Blaster / penetrating oil too! Not sure if this method will work in your case but it may.

I feel your pain It is extremely difficult to remove the piece of easy out...which really needs to be your first plan of attack. Try a dremel to make a small opening on each side of the broken Easy-Out and see if you can get some needle nose pliers or a pair of flat blade screwdrivers in to loosen it up and get the piece out. I had a caliper with a broken Easy-Out...had to take it to a machine shop and they could only remove it with a plasma cutter!!! Hopefully you'll have better luck. If...sorry...when you get the piece out then (assuming your hole is near center) you are best to drill out all remaining bolts and use a tap to chase the threads. If the old bolt material is removed from the start of the thread (i.e. where the bolt first touches the head) then re-tapping will likely follow the old thread. Hopefully this will help you avoid a thread insert...your last choice.

Good luck!

I had the same problem a couple of years back.
I used a dremel hobby tool ( I will find out which bit I used as I know it was the only one tough enough to grind down the easy out ) it was basically very thin and had a slight taper on it
I think it was this one I will double check for you

http://www.dremel-direct.co..._Grinding_Stone.html

any way this was tough enough to slowly grind down the easy out out and the allow me to work on getting the stud out of the head.

good luck and patience pays off

jon

Find out if there's a machine shop that offers EDM bolt removal in your area. It will get the bolt out and save the threads, even if the EZ-Out is broken off.

i think i will try some of the dremel ideas tomorrow and see how it goes. if i cant get them out i guess i will try a shop, hopefully they wont break my wallet since theres only one in my town

l also used a carbide bit in a dremel tool to grind away some of the old stud to let the broken easy out go. Took patience but worked.

Don't even waste your time with drill bits or easy outs. Use these with your dremmel:

http://www.lowes.com/pd_948...6page%3D1&facetInfo=

Then go to Napa and get a Helicoil kit. These things are SO easy to use. I just did one of my exhaust manifold bolts after I broke TWO easy outs in the hole. Dremmel cut through the tool steel better and faster and easier than drill bits on their best day! You may need several of those grinding stones because they can fly apart before they get ground all the way down.

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Jonathan

'68-69 GTO Nose - The Project has Begun!
My '85 L67 Build Thread

I did the same thing, except I tried to use a cobalt drill bit to remove the easy out. You guessed it. Broke that too.

There are diamond tipped bits available for the dremel. You don't actually need a dremel. The bits can be chucked into a regular 3/8 drill.
I wore out one or two of those bits, but they did remove the carnage.

I ended up damaging the threads and had to install a heli-coil, but it worked fine.

[This message has been edited by Raydar (edited 10-23-2013).]

That's the dremel bit what Boostdreamer has posted.

this as other's have said will fit in a drill etc.

it will grind down the easyout providing you take it steady - what you may find also if it is the exhaust manifold stud that it they are not screwed all the way down into bottom of the hole of the thread - I used a small drill bit and carefully drilled through the stud and not in to the head (you will feel it once you've gone through the stud).
I then used a 6.8mm bit to open the hole out and then a 8mm tap this then basically took it back to its original thread and I found that old stud came out with the tap - use plenty of pb blaster before attempting to tap it out and only if the hole in the stud is central.

patience is definitely the key.

good luck
jon

How good are you with a torch?

Heat the easyout (or tap) with a torch and the hit it with a chisel and hammer. The easyout should shatter and can then be picked out.

[This message has been edited by olejoedad (edited 10-23-2013).]