broken top cap stud bravo XR
 

working on sons AT stud broke off just below housing surface, pulled drive, have drilled with left hand bits, tried EZ outs, has not budged, any idea's ? thanks Rob

let WD 40 soak in the hole overnight.

If that doesnt work, heat it.


Something you should do anyway is drill & upgrade all the studs to 7/16. I swear it makes them flex less and have higer torque on the bolts.

already is 7/16 been sitting overnight now, was not sure how to heat with being assembled

Its not the stock 3/8? How the fuch did you break a 7/16 stud? They usually strip first... Was it a real stud or was it some ordinary steel?


With the topcap off heat the inside corner with a propane torch.... At least thats what I did.

Lay a 1/2" nut on top of the stud and weld the nut to the stud. As soon as it stops glowing red, put a wrench on it and back it out. The heat should make it come right out. May have to repeat it a few times if the nut breaks loose, but be patient and it will come

Probably corroded in due to be dissimilar metals. PB Blaster soaking overnight and then heat.
ATF mixed with mineral spirits is also a supposed to be a very good penetrating solution.

soaked couple of days now, tried heat, cold, been drilling a size or so at a time, right to edge of threads, no go, going to just helicoil at this point, frozen worse than I even saw...

it was broken off below the surface of the housing..knew the weld trick but did not think could get enough contact to weld

Always use gold/brown anti-seize for dissimilar metals on reassembly

Because its a F'in boat, LOL. Its a nice stainless stud. Im sure its from Max Machine Worx, as thats whos drive shower is on it.

As stated above. Weld a nut to it. The weld won't interfere with the case, because its alum.... This will work...

Come up to Northern New England and work on some cars/trucks with us. You'll find a new defenition of stuck/frozen/corroded/ball buster/screw this youcan't pay me enough....feelings...lol.

I'm sure the marina guys that work at the ocean feel the same pain.

Calcium chloride, I am personally convinced it is the best adhivse ever made for any type of metal. I am not sure why they even weld cars these days. All they would have to do is put all the panels together dip the whole thing in a tank of calcium chloride and they should be good to go. Think of the weight savings of all the unneeded welds and bolts.