Broken HSS drill bit in broken Stud. Assistance would be great!

TGIF : toes go in first ......thank-god it's Friday ..... this guy is first ..... uhmmmm ... did I win?

" Don't WORRY BE HAPPY "

" Happy New Year Guys "

Hey Mainlander! Sorry to hear of your troubles, but is it possible to just put a shorter stud in there when putting the manifold back on? Leave the broken stud and drill bit in the bottom? Or if the drill bit leaves not enough thread, snap it off flush with the stud somehow, maybe by belting the top with a small cold chisel? Anyways good luck with it and hope you have better luck from now on!

Good information here. This topic is better served in the Shop Talk Forum.

Well the sod of a thing is out!
First try was using mig to attachna 3/8 hex nut on to the stud.
Nope. Nut screwed off

Second try: More heat and bigger nut and mig filled the centre and then spiraling to the top of the nut.
Nope. Nut certainly had a greater tension before it wound off but failed it did.

Third try: Cobber reckoned he could do a fair bit of removal using a plasma cutter. Interestingly, the broken HSS bit was zapped out far easier then the broken stud. Had to use a long thin punch to remove the slag and then he blew out the loose slag with the air from the plasma cutter. Then I used the Cobalt LH bit and a bit of lubrication but the slag was too hard for it so Bill got in there again and delicately removed as much as possible with the plasma cutter. He was very careful and took his time and did an excellent job. I then drilled a bit more then with some difficulty, ran the tap through it. Ist a tapered tap but the hole was too shallow but the threads had managed to be started for the blind hole tap.
The thread is ok and will probably be ok but I don't want to chance it with a possible revisit so I'' take it that last step & will re-drill & tap it out larger and make up a whitworth stud with a 3/8 shaft but half inch on one end and 3/8 on the other. It will be cheaper than running a Helicoil into it. That way, the visible brass nuts will be the same size for aesthetic values. I want to show this old girl in the coming Agricultural Show and maybe other events.

This link is shows the same motor but is in the UK. Not mine but a beautifully restored one don't you think?
http://www.youtube.com/watch?v=t-hj98HqA4o

Thanks al you guys who have the skills and are so wiling to share. HAPPY NEW YEAR to you & yours.
Cheers.

Well done. I started to think when you said Whitworth I am a stationary engine restorer as well so am very familiar with those threads

Thank you very much for walking us through this to the end.Some of us have been on the edge of out seats since this first posted.It is interesting to me because of the new technology which most of you guys already know about,especially those that do this routinely but I thoroughly enjoy the new processes that,in my estimation still requires thought and experience as each job is different and requires different techniques to a successful conclusion.You have helped many of us here.Thank you.Ron G

Glad it worked out for you, and thanks for the update! I hate when we all give suggestions and then never hear what happened. I have used a torch to cut out bigger studs in cast iron, but I hadn't thought of a plasma cutter, probably because I don't have one.:beatsme

Thanks again, Mitch

Yair...Mostly on this site folks come back with results...not so much on other boards. Good that you got it sorted Kiwi.

Any one have any comments about the Plasma?

It's new technology to me, I didn't realise it leant itself to this sort of problem fixing

Far out! I am humbled by the comments I have received just now.
Goodness, it's me that has been ever so greatful to you guys as many, if not most have probably far more experience than I. I have been a guy who has played with wood mostly. It's only in the last 4 or 5 years that I have taken to restoring bits & pieces of machinery. I have alway tinkered with machinery but nowI take on the challenge of getting inside the gadgets and see if I can make repairs. Maybe 'cause it's of my age 59 (I think) that I see the skill of the old folks from the early 1900's and wonder about the lack of technology compared with today. We have some amazing tools mow and I am dumbfounded when I see things achieved from the past. Maybe it just because I am dumber than I thought and many or most have far more grey matter that work than I. :beatsme


:notworthy

Happy New Year. Be safe ay and again, tanks

Glad you finally got it out, it has been an interesting one to keep check in to read the different ideas. There were some pretty darn good ideas and I have used many of them over the years. Good to know you are preserving some of the old machines. It is amazing how so many things were done with pretty simple machines. I have always been marveled by pocket watches, and how they made so many of those little parts so accurately.

take a punch and hammer and crush the broken bit,keep pulling the crushings out with a magnet!