Removing a broken bolt the easy way

[Paul Buhler]

Deleted: I got tired of looking at my poor joke whenever I checked this thread. Paul

[Howard Yoder]

I have done about every thing mentioned here except the copper tubing I really like that idea as I'm getting blind as a bat in my older age and don't do things as often as I used to so I need all the help I can get to do a better job

[Ray III]

Some great tips here. Someone makes a welding rod just for this purpose, Extractalloy I think it's called. I've seen my dad take out many bolts that were broken halfway down the hole, welding straight out without letting the arc touch the sides, then putting a nut at the surface and welding to that. He's good at it though.

[jsal]

another way i use quite frequently is heat red hot with a rose bud torch quench with cold water or let cool over night and have done all that have been mentioned.

jim

[Lavoy]

The rods I have used for pulling studs or bolts are Supermissleweld and High Ally 400 (might be 500, can't remember). They are a high elongation stainless with a super tough flux, the arc will not blow out throw the flux if you touch the side of the hole with the rod.
Lavoy

[gus]

I have a broken manifold bolt on my truck. Aluminum heads that I don't want to damage. It's broken just below the cast iron manifold and not an easy reach.

Suggestions???

[Lavoy]

If doable, I would be inclined to pull the rest of the bolts and get the manifold off, then see if you can get at the broken stud. I normally try not to use this method out of position, but that may be more a function of my welding skills.
Lavoy

[Ray III]

Aluminum expands faster than iron so try pliers while the engine is still hot from running.