[Vwdiesel] broken stud

[Val Christian]

Since it's a small stud, and in an Al head, I avoid stick welding.
Probably just me.  In the order which I would attack:

-low vis penetrant (PB Blaster is pretty good)

-prick the center with a center punch.  Tap it 30-40 times, and 
pur on more penetrant a couple of times.  Let sit overnight, if 
schedule permits.

-tap more, with penetrant.  Try vice grips.  If it's not going to
move, then I goto torch.

-small oxy acetylene aircraft torch.  Carefully heat stud, NOT
red...just a short heat.  You want it to expand, not melt the Al.

-penetrant, vice grips, and some tapping with the center punch.

If you don't have a torch, more tapping may be helpful.  Remember,
oxides of metals are harder and more brittle than the metals.  So
the tapping is intended to crush the oxides.  The penetrant helps
create a slurry to carry away or at least let the oxide particles
flow, while you turn the stud.

Be patient, because you can get it out, without damaging the 
casting or breaking the stud.




> 
> If you're equipped, welding a bolt to the stud gives you a bolt head to turn and often breaks the corrosion hold on the remaining stud.
> 
> Rudy <petersenrudy at hotmail.com> wrote:  I was removing the water flange on the end of the Head on my Jetta today and
> broke off the stud that secures the water pipe and flange. There is about
> one quarter inch sticking out.
> 
> I imagine its probably going to be a one time try so looking for suggestions
> from someone who's been there.
> 
> Rudy
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