Looking for ideas!

[reevsy]

Looking for ideas? I have to remove a long stub from my cylinder block after a blown head gasket burned it through level with the head! All suggestions welcome well most of them.

Edited by reevsy on Wednesday 1st August 21:50

[GreenV8S]

Maybe a trick of the light but I don't see a stud in that hole. Is it actually flush with the head? If so, you could consider tapping it off center with a drift to ease it out, or welding a nut to it (this could easily damage the block and need it resurfacing). The stud should unscrew quite easily since there is now no tension on it.

[227bhp]

What is a 'long stub'?
Top lurking btw.

[Graunching_dave]

What engine is that?

[paintman]

Drill a slot in it with a Dremel to take a screwdriver blade. Done that a few times in the past.

[227bhp]

No word from the OP.
Looking at it with fresh eyes I think it's a coolant carrying sleeve which was screwed in and is now flush with the top of the block, several tools spring to mind:
A left handed thread tap or drill might grab it.
These:
https://uk.rs-online.com/web/p/products/4236685/?g...

Or these: https://www.ebay.co.uk/p/Snap-on-15-Pcs-Screw-Extr...

Or just Google broken stud extractor/removal.

[reevsy]

the Engine is a 1927 Rolls 20 the stud is just below the surface in a tube passing through the block down into the crank case. Suspect the gasses from the blown head gasket heated the stud to the point it stretched and parted. Can’t get a dremol in not much clearance between the wall of the tube and the stud which is on of the studs holding the cylinder head Down. The engine is in very good condition it’s in three parts the cylinder head, the block, and the chest at the bottom. The studs are not rusted in just need to find a way to grip this damaged one!

[Peanut Gallery]

Random idea - center punch a decent mark into the middle of the stud, possibly even a gentle drill, then use an impact driver with a philips screwdriver head?

https://www.ebay.co.uk/itm/IMPACT-SCREWDRIVER-WITH...

[227bhp]

Drill it and use a broken stud removal tool.
If it's seized so solid that its snapped no lightweight ideas will work.

[HustleRussell]

Centre punch it

Try to drill a hole down the middle of it with a left-handed drill bit

You might find it tries to unwind as you drill it, if it doesn't unwind you have created a hole for an EZ-out or similar.

[GreenV8S]

227bhp said:

If it's seized so solid that its snapped no lightweight ideas will work.

Apparently it was burned through, not snapped.

[voicey]

HustleRussell said:

Centre punch it

Try to drill a hole down the middle of it with a left-handed drill bit

You might find it tries to unwind as you drill it, if it doesn't unwind you have created a hole for an EZ-out or similar.

This all day long. LH drill bits are brilliant for getting snapped fasteners out.

[paintman]

reevsy said:

the Engine is a 1927 Rolls 20 the stud is just below the surface in a tube passing through the block down into the crank case. Suspect the gasses from the blown head gasket heated the stud to the point it stretched and parted. Can’t get a dremol in not much clearance between the wall of the tube and the stud which is on of the studs holding the cylinder head Down. The engine is in very good condition it’s in three parts the cylinder head, the block, and the chest at the bottom. The studs are not rusted in just need to find a way to grip this damaged one!

Not even using the flexible extension?

[227bhp]

GreenV8S said:

227bhp said:

If it's seized so solid that its snapped no lightweight ideas will work.

Apparently it was burned through, not snapped.

Sorry you're right, difficult to comprehend that happening I suppose.

[GreenV8S]

227bhp said:

difficult to comprehend that happening

Yes. Seems more likely it has suffered accelerated corrosion from heat + acidic water rather than literally burned, and we don't know whether it failed when the nut was removed or when the stud was being taken out of the block, but either way I suppose it had been significantly weakened.

[reevsy]

The stud was blown out into the rocker housing. This is the stud.

[reevsy]

And the head gasket

[GreenV8S]

reevsy said:

The stud was blown out into the rocker housing. This is the stud.

Wow.

Is the broken end of the stud corroded similarly? That would make it very difficult to remove.

How bad is the damage to the head and block? If it's anything like the corrosion on that stud, I wonder whether the castings have also been scrapped.

[reevsy]

Thankfully the block is good with no damage to the face or the head.

[reevsy]

So! and it may help others. I made a tube that just fitted inside the recess about 1mm clearance, this tube was drilled slightly smaller than the broken stud itself but when heated and expanded slid over the stud and down the stud with a genital tap. Allowed it to go cold and shrink onto the offending stud, with a little help from a light tapping with hammer the stud released. 🙂