Broken exhaust stud removal...

[gerard]

Got the drill bits, pneumatic drill and compressor and the RACO screw
extractors out today. I let the stud soak in penetrating spray for a
long time. Then I slowly drilled the broken stud, put in some more
penetrating spray and spent another hour removing the other 8 complete
studs from the head. One of the studs have been removed long time ago,
but the remaining 8 turned out to be a complete mission to remove. A
slow process got them out

Sounds like a good story so far, huh? Not quite.

The last remaining stud was coming out nice and slow. And then it broke.
Some of the thread is sticking out.

As for the screw extractor, the so-called eezy-out *cringe*... well, I
have half left. It broke off too! I bored the hole in the stud to over
4mm in order to use the larger eezy-out *cringe*. I didn't even use much
force, the penetrating spray seemed to have loosen the stud a bit as it
did begin to move.

What now? Must the head come off and go to an engineering shop?

I'm going to buy some weird stuff I saw a while back at a engineering
supply store. It's a powder and a small tube of liquid activator. Put
the powder down and then put 1 or 2 drops of the activator on it and
there's a small puff of smoke and everything goes rock solid. Bonds
everything in contact with it, just forms a solid chunk. It's less than
$5. I reckon I'm going to get this odd stuff and try some on the top of
the eezy-out *cringe* broken off in the stud and put a small rod in
contact with it and see if I can turn the eezy-out *cringe* back out. I
still want to find out what the bond strength is on this stuff.

Any suggestions on how to proceed will be welcomed.

I never ever win, do I! :(

G.