After three years of rebuilding I was trying to get my car on the road this summer to finally enjoy it when disaster struck!  I was rebuilding the clutch linkage and installing a BRAND NEW ball stud to the engine block that the cross shaft rides on when the stud broke off in the block!  I didn't even apply much force so I'm thinking I was sold a cheap re-build kit (from a major Corvette Restoration supply house) but thats a topic for another post!  I think you know what happens next.  I try to center punch and drill the broken bolt in order to insert an EZ out and pray that works, well it gets worse!  The hardened steel drill bit broke in the bolt.  Not sure if there is another kind of bit I can use to drill IT out, diamond tipped?  At this point I packed up my tools in disgust. I sure hope I don't have to pull the engine to get this fixed or I will certainly spend another summer driving my Honda!   I'm considering welding a rod to the bolt to turn it out but it broke off flush with the block so I don't know if that's possible.  If anyone has any suggestions or knows of a good shop in Central Jersey that can help, it would sure be appreciated.  Signed: Discouraged in Jersey!

I feel yer pain brother...I feel yer pain....btdt.

However...there is hope. There are brackets available to use for the blocks that do NOT have the hole for the clutch ball..not all were drilled/tapped for it. The bracket actually bolts to the bellhousing. I can't remember where I've seen them, but I do know they are available. Might do a search, or check a Hot Rod/custom builder website to see what is available. I'll look and see, too....

Try Summit:

http://www.summitracing.com/parts/OER-3932760

All is not lost.  A few years ago, I was working on my 1929 Chevy and managed to break off one of the exhaust studs into the exhaust manifold.

I tried everything from easy-outs, a torch, and every brand of gunk there is out there to no avail.

In desperation, I was searching the internet and came across a company in nearby Orange County that claimed to disintegrate broken studs and restore the part.

I dropped the exhaust manifold off at Noon and picked it up at 4pm.  $70.  You couldn't tell there had ever been a problem with the piece.

Here's a company in Long Beach California to give you an idea.  http://www.kleinindustrialservices.com/metal-disintegration.php

I know your part is not the same as a manifold but some of these companies make house calls.

Anyway, good luck.

Jim

This is the company I went to, just found them again using a search for "broken stud removal."  My results are all local to me via google but your results may be near you.

http://www.brokentap.com/index.html?gclid=CPGOy5qG_q8CFSo0QgodHDboRA



|UPDATED|5/13/2012 1:02:42 PM (AZT)|/UPDATED|

Wow!  You guys are great!  I knew I would get help on the forum.  (On Mother's Day no less, hope I didn't get you in trouble!) I'll look into these suggestions and keep you posted.

Boken bolts do bite....  you might, just might be able to drill it out even with the other bit broke off into it... by using a 'left handed' drill bit.  Not sure about the size of the bolt that is broken, but somehow 5/16 comes to mind, maybe 3/8...but, might be worth a try with a lefty drill bit, if it catches it could twist the bolt out... fingers crossed for ya !!! 

I too am completely impressed with the knowledge you guys have.  I am good at detailing, but at mechanical work...I SUX!  The knowledge you guys have can ONLY be accumulated through experience and no one can teach that (except at the "school of hard knocks").  I truly wished that I lived closer to some of you guys (for the southern fols that would be Y'ALL).

You might try a good punch, if you can get at it try to get on the outer edge of the stud and tap it to unscrew it. If it's flush this might work for you and not mess anything up. Good luck!

I would try the punch thing too..from the sounds of it you were installing the new part..it may be that the punch may work as the threads should not be completely seized..if you can find a small punch of a decent length it may get it out..make sure you hit the easy out as it may loosen it on the way out...I have a tool I bought years ago that has fingers that go into the 4 spots on a 4 sided easy out...it works sometimes..but it usually just got bent...I have 3 types of easy outs...they all look brand new..I don't use them because of this issue.