I figured this would be better for the fab section then the Fi section. Anyways I was bolting my 5 bolt downpipe up and I have to use 4 bolts and 1stud with a nut. The stud broke off flush in my turbo housing. Any ideas on how to remove it? I don't wanna do the ez out way because I've heard of them breaking off and this stud is in there good. Considering I was using 2 12mm nuts double nutted trying to back it out when it snapped. So any help would be great. The manifold and turbo are still bolted to the motor but obviously can be removed if I have too. Thanks in advance H-T

 

Maybe try a left handed drill bit..or take it to a machine shop.

 

I don't feel like taking the manifold off and paying them to do something I can do. Already had to get a mount hole heli coiled. What's a left handed bit going to do for me? I thought you used that first then a screw extractor/ez out

 

left handed drill bits make it so they bore in the direction of extraction. So as you bore the middle out, the heat, and the weakness of the metal helps the stud come out as ur drilling.

 

Weld a nut to it

 

Ok I'll pick one up then.
It's totally flush so I don't think I can weld to it.

 

I used to work for the local turbo rebuild shop here and had to remove hundreds of snapped studs.

Heat up the snapped off stud with your tig torch.
Heat it up just so it melts and the material pulls away from the edges of the threads.
You may need to heat it for a good minute or two to make surethe heat gets deep down. Take your time.
Then add filler so the puddle is equal diameter to the stud. (don't melt the filler to the casting)
Then just keep building up filler so you have a tower that is the same diameter as the stud.
Then place a nut over this tower and weld the tower to the nut
When you loosen it go forwards and backwards very slow and fast but with little force.
It should break loose now.

I've been able to remove every snapped turbo stud this way. Sometimes the threads get ripped out too and you need to heli-coil but the stud always comes out.

 

 

or hold a nut over the stud and hit the middle with a mig

 

I'll try the nut idea. Done it before but there was a bit more stud.

 

i had one less than flush and a mig nut and backed it out...the heat will help...

 

Adam same thing happen to me i did it the same way as sdubfid said.. if josh dont have heat i live 5back min away u can bring it up... lmk