Hey Guys,

I have a top cap stud broken off on this upper. I would like to get this broken stud out before sending it out to be rebuilt. Any ideas? Should I just leave it to whoever I choose to rebuild the upper?

Thanks!

Not great pics, but you can see it's broken down pretty low. I've been reading that EZ-Outs are a waster of time. I don't have access to any welding equip either.

got a harbor freight near ya ? If not, online.

Get a cheap-o propane torch, an e-z out set and a good drill bit set. youll need a candle too.

drill the stud so you can deeply insert (oh boy, here comes the responses) the EZ out. with the EZ out firmly in place, melt some wax down in the hole over the top of the stud. Now heat the outside of the case til the wax disappears. wait til it cools some and back that broken stud out.

Never heard of the wax trick but sounds feasable. Most easy outs I have seen come with left hand bits, you might get lucky there but I doubt it. Be careful not to heat the easy out or it will twist & break. Try drilling a pilot hole through the stud & put some liquid wrench or such under the stud, then when you heat it the stuff will boil its way up the threads.

The wax trick works.. Helped a buddy pulls his drives and they were salt corroded on.. drilled a hole, melted the wax in and let it cool.. rubber mallet broke it loose.. I had my doubts it would work but it sure did.

If the stud is frozen, I would spot weld a nut to it.
Regarding the rebuild, I would recommend Mr Gadgets. Super nice guy!

I worked at a die cast company,and we had big chunks of bees wax just for broken and stuck bolt extraction. it works!

I use a left-hand drill bit to drill a pilot hole...90% of the time,it will unscrew the stud while digging thru it.

Once you get that stud out, I highly recommend putting time-sert or heli-coil the holes. It will make them stronger going forward. Not a good design by Merc to have steel studs threaded into aluminum.

Smitty

Mission accomplished!

After f'in around with my cheepo drill bits, I went and bought a nice bit. Drilled all the way through the bottom of the bolt. I was afraid I hosed up the case but I backed off as soon as I felt the bit go through.

The ez-outs I had were not much help. I ended up pounding an allen wrench into the hole and then turning it with a small piece of pipe.

I noticed that the other stud I removed was bent too.

Thanks for the ideas!