Broken Dilavar stud removal
 

Has anyone had any luck mig or tig welding a nut to a broken dilavar stud for removal?
If a dilavar stud breaks flush on the engine, has anyone got them out? what methods?
thanks

Wil:

I've had excellent luck with TIG welding a nut to the stub of a broken stud and then heating the case to back it out.

If it breaks off flush with the case that results in nothing to weld to, the only way you can get it out is by EDM machining.

There is an excellent technique where you rosette weld a washer to the flush stud, then weld a nut to the washer. I have never used this technique (knock on wood - cause I have never been there) but have heard good things.

Good luck!

tadd

All good methods. One thing to remember is that if you weld the nut on a very short stud piece be very careful not to damage the piston spigot.
It also helps to strike the welded nut with a mallet after it is welded in place. This helps the threads to release in the case.