[Jacques Reed]

From what I have read and heard The welded nut method is by far the best way to remove broken studs from a block but just thought I would add this method to the box of tricks and for general interest.

I will be the first to admit this method is labour intensive but it did get two broken studs out of my Flathead Ford block in 2002 BDP (Before Digital Photography) without the use of oxy-acetylene or MIG.

I read about this technique in "Restored Cars Magazine" in the late nineties.
The article said to drill a hole in the stud and then using a junior hacksaw blade in a holder carefully cut two notches on either side inside the hole in the broken stub being careful not to go too deep to the internal threads. The stud can then usually be screwed out with an easy out or in my case they screwed out with a screwdriver after I tapped the sides of the stud with a pin punch.

My concern was how to drill a hole down a stud without wandering off center or drilling it at an angle and thereby damaging the threads in the block.
The solution was a $40 small drill press I picked up at a garage sale. I then cut down the post and reversed the drill head on it to get the chuck close to the block. I used studs to bolt the drill press base to the block then a careful centre punch followed by a centering bit before drillling got me straight down the centre of the stud.

I think I used a 3/16" diameter drill down the stud. I made a blade holder and ground a bit of the hacksaw blade away to fit the 3/16" diameter hole.

Long time ago but probably took just over half an hour to get the first one out. Second one went a bit faster.

Don't profess this to be a great method but it did work and unlike some bad tips in books about using easy outs to remove broken studs you won't wind up with a broken easy out stuck in the block!

Cheers,