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Thread: Removing head bolt studs in aluminum case

  1. #11
    Join Date
    Nov 2018
    Reno NV


    Swolf, if i have to remove a broken stud, the last resort is an easy out, with the expectation that it will probably break. I have used various designs similar to easy outs, with various success.
    I haven't used the fluted EZ outs, but they get good reviews, depending on brand. Some are soft.
    I wouldn't use the hollow cutters as I expect they would wander off and damage the cases.
    An interference fit bolt is always going to be difficult to get out.
    Another method that has a good chance is welding a nut onto the broken bolt shaft, if there is enough sticking out to get onto.
    The best option is the have a beer and hope it jumps out itself.

  2. #12
    Join Date
    Sep 2010


    There is a drill called a Rescue Bit designed to be hard enough to drill the EZ out. You can also have it burned out at a machine shop with a EDM type piece of equipment.
    Jim D

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