Broken Bolts / Studs..... What's the SECRET?

[4Gears4Tires]

I think you are fully into the janky repairs territory if you don't pull the head. I'm not sure you can get good enough heat into the head to weld it, if you can weld aluminum, if the head is still on the engine. So...

Jam a good bit of JB Weld SteelStik down the hole, thread a bolt in, then remove the bolt. Jam a bit more in. Thread the bolt in and out. Then a minute later thread the bolt back in, and out, etc. You want to keep the threads clean. Wait 24 hours for that to really set. Maybe chase the threads. That might be enough to "fix" it.
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'87 Syncro
Ferric Oxyhydroxide Superleggera Edition

[dschaftlein]

I was replacing my old rotten exhaust today and broke a header bolt just below the surface of the head. No big deal I’ve had good success with drilling out broken bolts before.

Well I should have walked away and dealt with it tomorrow in the daylight. Despite stopping and checking the depth I still managed to drill too deep. My heart sank when coolant started gushing out of the hole. How embarrassing!

Does anyone have any thoughts on a repair? I’m hoping I don’t have to pull the head to repair or replace it.

I was thinking about installing a stud in the hole with some hi temp sealant Or jb weld it and hope for the best... any thoughts?

[djkeev]

Quoted entire post and added here......

[swharris]

Well, one more post confirming the weld-O-nut strategy. Had a stud that was stuck incredibly bad. I snapped off at the surface. I luckily could get an 1/8th of a turn of a rocker nut on it. Welded it up solid and then shocked it with "Freeze Off" and with a few back and forths she came out clean. Threads were easily cleaned up. It's worth getting the welder out. I will go this route from now on.

[Vanagon Nut]

[swharris]

[warmblood58]

and part of the problem of dissimilar metals reacting with each other via electrolysis and galvanic corrosion . . . I got lucky with heat and wax recently. Year ago, I did volvo exhaust manifold studs that were well known to snap easily upon removal - the process took five days of heating/pb blaster soaks. Sometimes, time is your friend but it is a pain to proceed so slowly!

[Halifaxwesty]

Had awesome success getting this exhaust stud out...hammer on sacrificial 8mm socket.....small bead of weld...and 3/8th impact...out first try...

After heating it red hot...and using some lube no luck....
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84 Westfalia Vanagon
2.2 RMW Conversion
Work in Progress

My first car was a 1968 VW Bug

[kalispell365]

I often use these with quick bursts delivered with a 3/8 impact gun. You can use smaller sizes for broken studs, they really grip!

http://buy1.snapon.com/catalog/item.asp?item_ID=641938&group_ID=680941

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Moderator added photo of item being linked.........

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1983 Diesel Vanagon Westfalia chassis with Subaru 2.2l

[pushkick]

i guess if you had to you could take it to a machinist and they could use a water jet if you cant get a grip on the broken bolt.
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i see said the blind man to his deaf dog
i am going to quit smoking and drinking and die a healthy man. gotta laugh
there is no deed to the planet earth
1990 vw automatic camper

[djkeev]

I had these two bolts break off 7-8 years ago. Never bothered to fix it, always something else to do.

So they were seized years ago and sat in the weather broken for 7 years.

Cleaned off the rust, used a torch to heat up the captured nut to red hot, liberally applied Candle Wax, clamped on the vise grips and wiggled them left right left right and then unscrewed the remnants.

Almost as easy as bolts with a head!

Dave
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Stop Dead Photo Links how to post photos

Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473

Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert

[pushkick]

i would think if you could take the head or whatever part to a machinist they could mill out the broken bolt very easily with a direct plunge bit.
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i see said the blind man to his deaf dog
i am going to quit smoking and drinking and die a healthy man. gotta laugh
there is no deed to the planet earth
1990 vw automatic camper

[Wildthings]

I am thinking of buying an induction heater. That way I can heat a broken stud or bolt red hot from one end to the other while inside the aluminium head or case.

Two summers ago I spend way too many hours trying to remove the exhaust studs from a Type 4 head and was quite afraid that I had used so much heat that the heads would give trouble in short order after being put back in service. I also have at home a couple of WBXer blocks with sheared head studs that an experienced mechanic gave up on.

I might start by finding a rental induction unit and seeing how it works to learn whether it is worth the price or no.

[Merian]

That piece of "art" is why others make fun of VW owners.

[MarkWard]

Quality bolts are rated among other things for clamping force. What you see in the picture is "clamping" force. Gets you down the road and cheaper than a rental car.
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☮️

[Jake de Villiers]

[insyncro]

[RicoS]

[T3 Pilot]

For when you can't use heat, or don't have a welder use this:

Quickcenter

http://www.quikcenter.com/application.htm

Works consistently well.
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1988 Vanagon

The most important part in every vehicle is the nut behind the wheel......

[Vanagon Nut]