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I know I have one stud broken about 1/4" inside the head. Sure to have more. I have a mig welder and feel confident that I can weld the studs. So for those that have welded up a stud to lengthen it out of the hole and add a nut to remove it how did you do it? My first thought is to center the wire in the hole and use short pulses/tacks to build puddle on top of puddle till it comes out of the hole. It's only about this far [ ] Probably a low heat and wire speed. Any other ideas or horror stories? Thx
That's exactly how I did it I kept building up te weld till I could weld a flat washer to it then I welded a nut to the washer then I soaked it in pb blaster and used a short breaker bar and just kept easily back and forth till it broke free
You've got the plan, just be sure to use high enough heat to get good penetration or you will twist the puddles off before the bolt backs out. That's how I got mine out.
My biggest concern is messing up the aluminum threads. Thanks for the tips.
You won't unless you completely loose your mind with the MIG.
The Alum heads/threads will survive quite a bit of exposed steel welding without troubles. It's kind of like me in a bar full of young gals, they simply aren't attracted!