How to Remove a Broken Stud Using Welding

You can use welding to remove a broken stud without damaging the threads of the hole in which it is screwed. Both TIG and MIG welding will work for this task. Heat the welding metal to the temperature that's appropriate for the type of metal you decide to use.

Things You'll Need

• TIG or MIG welder
• Welding metal
• Washer
• Bolt
• Socket
• Impact gun

Instructions

1. Fill the recess by welding metal to the top of the broken stud if the stud is broken below the surface. If the stud did not break off below the surface, skip this step.

2. Weld a washer to the front of the filled recess, or the top of the broken stud. Use a washer that's larger than the stud.

3. Bond a nut to the top of the washer by welding them together. Use a nut that's about the same size as the washer.

4. Let the newly welded area cool completely. Heat the area surrounding the stud with the welding torch to help loosen the stud if it's corroded.

5. Use a socket to turn the welded nut so it very slightly tightens the stud. This will also help loosen a corroded stud.

6. Turn the welded nut to loosen it and remove the stud. If the stud still does not loosen, use a very low setting on an impact gun to turn the nut.

Tips & Warnings

• If you're welding with cast iron, heat the metal until it turns red before you attempt to weld it.