 Anyone ever break a head stud?, Looking for ideas, tools success stories, horror stories, what cha got |
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| rick 918-S |
 Apr 27 2008, 04:56 PM
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Hey nice rack! -Celette  Group: Members Posts: 20,785 Joined: 30-December 02 From: Now in Superior WI Member No.: 43 Region Association: Northstar Region 
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I'm building a 928 hybrid engine which is comprised of a 5.0L 32 valve short block with 16 valve euro spec "S" heads, spyder and CIS from the 4.7L "S" engine.
I stole some time from my busy work schedule to prep my 928 block for the machine shop. The head studs need to be removed for the boring process. Now I've pulled studs before without incedent. But as Murphy would have it, this time I broke one of the studs flush at the start of the threads. So I have the threaded section ( 1 1/4"long ) hardened head bolt stuck in the block. Normally this wouldn't be a problem, but the stud is free standing in a 3 1/2" deep hole in the block! Here's a crude drawing of the problem I'm faced with.  Here's the stud.  Here's the stark reality of the stud in and out of the block. The stud slides down a 3 1/2" deep hole in the block before it starts to thread in.  I'm going to make a drill collet as a guide for a pilot bit. The problem is I need a long, reverse twist drill bit. Most drill bits are approx 5" long. the hole is 3 1/2", the threaded section is 1 1/4" for a total of 4 3/4". See the problem? Then, what the #$!! do you drill a hardened bolt with? Anyone know of a good tool source? This is beyond most Mac and Snap on stuff I would think. |
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| Richard Casto |
Apr 28 2008, 08:14 AM
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Blue Sky Motorsports, LLC Group: Members Posts: 1,465 Joined: 2-August 05 From: Durham, NC Member No.: 4,523 Region Association: South East States |
I have no idea what the cost of this is, but EDM (Electrical Discharge Machining) aka Spark Erosion may be the right tool for the job.
Maybe you can find someone local to you like this guy (found via Google search)... http://www.brokentap.com/ |
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| Bartlett 914 |
Apr 28 2008, 08:22 AM
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#3
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Advanced Member Group: Members Posts: 2,216 Joined: 30-August 05 From: South Elgin IL Member No.: 4,707 Region Association: Upper MidWest |
QUOTE(Richard Casto @ Apr 28 2008, 06:14 AM)  I have no idea what the cost of this is, but EDM (Electrical Discharge Machining) aka Spark Erosion may be the right tool for the job. Maybe you can find someone local to you like this guy (found via Google search)... http://www.brokentap.com/ (IMG:style_emoticons/default/agree.gif) Totally! The drill guide should also work. The biggest problem is getting the drill to start in the center of the stud and not wander off center. Then you are drilling the case and not the stud. A properly setup EDM should be able to remove all the stud except the threads which may still be tricky to get out because of how deep the stud is in the block. Take the block to someone with equipment like EDM and / or a mill. Lots of luck Rick. |
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Posts in this topic
rick 918-S Anyone ever break a head stud? Apr 27 2008, 04:56 PM
Vacca Rabite Let your machinist deal with it?
Probably end up ... Apr 27 2008, 05:49 PM SGB Looks like a "major malfunction".
Wha... Apr 27 2008, 05:52 PM scotty b Rick the guy I started out working for had the EXA... Apr 27 2008, 05:59 PM spare time toys Could always use that spare block that came from C... Apr 28 2008, 03:02 AM
Richard Casto
I have no idea what the cost of this is, but EDM ... Apr 28 2008, 08:21 AM r_towle I believe the correct bit is made from Cobalt.
The... Apr 28 2008, 08:22 AM rick 918-S Larry, I broke that CA. block when I had a valve f... Apr 28 2008, 08:52 AM
rudedude Rick,
There is a tool dealer in st paul, Norseman... Apr 28 2008, 09:04 AM rick 918-S
Rick,
There is a tool dealer in st paul, Norsema... Apr 28 2008, 10:49 AM Richard Casto Rick,
If you go the EDM route, I would be curious... Apr 28 2008, 09:52 AM rick 918-S I contacted the EDM guy. He didn't think he co... Apr 28 2008, 10:23 AM rick 918-S BTW: My machine shop offered to drill it out and i... Apr 28 2008, 10:57 AM Cap'n Krusty A good EDM guy can probably do it. I have a numbe... Apr 28 2008, 11:32 AM kwales Aircraft work sometimes requires extra long drill ... Apr 28 2008, 06:58 PM rick 918-S OK, I did some deep thinking about this today. Unf... Apr 28 2008, 08:58 PM r_towle I bet you could get a new block for cheap....serio... Apr 29 2008, 11:02 AM r_towle Have you called 928 international??? Maybe they ha... Apr 29 2008, 11:03 AM rick 918-S
Have you called 928 international??? Maybe they h... Apr 29 2008, 11:27 AM Bartlett 914 What is the size and pitch? How hard is it? You ca... Apr 29 2008, 11:49 AM rick 918-S
What is the size and pitch? How hard is it? You c... Apr 29 2008, 12:43 PM Bartlett 914
With any luck the bolt will be a little softer ... Apr 29 2008, 01:20 PM rick 918-S The tools arrived today. All left hand or left twi... May 1 2008, 07:24 PM GWN7 To center the drill, find a piece of pipe with the... May 1 2008, 10:29 PM rick 918-S
To center the drill, find a piece of pipe with th... May 1 2008, 10:40 PM Bartlett 914
To center the drill, find a piece of pipe with t... May 2 2008, 08:46 AM rick 918-S
[quote name='rick 918-S' post='1027210' date... May 2 2008, 10:00 AM Richard Casto I hope this works out for you.
:popcorn: May 2 2008, 07:52 AM rick 918-S I ran a test tonight on the broken stud. The left ... May 5 2008, 12:24 AM Wilhelm I've had luck getting a stud out of a deep hol... May 5 2008, 04:23 AM rick 918-S
I've had luck getting a stud out of a deep ho... May 5 2008, 08:07 AM Joe Mama That's sounds like the best DIY idea. Other t... May 5 2008, 09:02 AM Dr Evil Well? May 8 2008, 01:21 PM rick 918-S
Well?
I can't get a break! I drilled th... May 9 2008, 08:47 AM Wilhelm
Well?
I can't get a break! I drilled t... May 9 2008, 07:59 PM rick 918-S No access from the bottom. It comes out through pa... May 9 2008, 08:56 PM rick 918-S I tried welding a piece of square tube to the bolt... May 12 2008, 12:22 AM |
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