Quote:
Originally Posted by Mudflap
My favorite method is to lay a nut over the broken stud and weld through the middle, then remove it with a wrench. I've ruined too many parts trying to drill them out.
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I've used this method most of the time. Only good if you have a welder, but yes it is probably the best way I have found. Another trick I have done is if it is broken off too far to tack a nut on and the only option is to drill. Take a piece of flat bar and drill two holes in it. One to slip over the other bolt and tighten down and the other hole it be a smaller hole like 1/8" to use as a pilot so the bit doesn't drift side to side when drilling the pilot hole in the stud for your easy out. This keeps the bit dead center of the stud. I've changed out too many broken studs in my life time and I have screwed up a few until my brother in law who has been a mechanic most of his life shown me that trick.