2010 - Volume #34, Issue #1, Page #36
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How To Remove A Stud That Has Broken Off Flush
Ken Greenia, St. Clair, Mich.: "To remove a stud that has broken off flush, I lay a flat washer over the broken stud and weld the two together. Then I weld a nut to the washer and remove the stud by working it back and forth. On a really tough stud, first I drill a hole in the middle of the stud and then jam in a small welding rod so I can heat the inside of the stud, which causes it to shrink and loosens it up. Then I weld the washer and stud together and weld a nut to the washer. I'm a retired Deere dealer, and over the years our shop mechanics often called on me to remove broken studs so I know this method works. I've removed literally hundreds of studs this way."
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