Engine mount stud from HELL

[Nick774]

So I have a big pain in the ass of a problem. We were nearly finished dropping the motor and trans in when I noticed on the passenger side engine mount, the rear end stud sticking out was gone, broken off. Removed the engine and have been drilling away and then I made a HUGE mistake. I was poking around in the drilled hole with a screw driver to check the depth when.....it snapped clean off in the hole and I can grab it with anything :jawdrop: HELP! What the #$%! do I do now.

[DMCMW Dave]

What snapped off, the screwdriver or the bolt (Stud)?

[Nick774]

the screw driver

[Dangermouse]

I think we need a photo to be clear.

[wafflemaster]

Is the screwdriver piece flush with the hole? If so, you might be able to use a MIG welder and tack it to another piece of metal and yank it out. I've done that when I couldn't grab anything and a magnet wasn't strong enough.

Option 2: put a small dab of JB weld onto another screwdriver and touch it to the broken piece. Let it cure overnight then hope it's just strong enough to pull out.

[SS Spoiler]

Memo........ Buy better equipment

[Ron]

It shouldn't be it there very tight (unless there is more to the story ;-), so maybe try a small Easy Out?

[ALEXAKOS]

In case I am thinking of another screwdriver.... mine were welded in there and snapped off the one side as well.
I juts heated up with a torch the hole, the engine is aluminum so it expands with heat more that the metal screwdriver.
Then took a same diameter screwdriver and knocked it out the other side.
Drilling out a metal screw from a aluminum housing is a bitch! All you get is sidewinded onto the aluminum:mad2:

[Nick774]

26914 you can see the screw driver inside the hole. its jammed in there about 3/4 of an inch

I drilled both ends of the bolt. One side is drilled only about an inch deep, The other end was about the same until the screw driver snapped off in it. As you can see the drill didn't stay centered very well either but I still kept angled into the center. Should I try Going from the other side again with a larger drill bit? I assume the screw driver is only a mild to weak metal. Would a good drill bit eat through it like the bolt or would it cause me more trouble?

[Ron]

FWIW- After looking at the pic, I still think an easy out may get the screwdriver out.

I'd try drilling from the other end with a bit somewhat smaller than the stud until I either got close to the screwdriver (note the bit will probably grab the screwdriver and break if you reach it) or it runs off center (if it does, stop and look at it as a good way to get PB Blaster or similar in there deep...no big deal really there), then try driving it out with with a large drift punch or slightly smaller, hard bolt). Soak, soak, soak!

[David T]

FWIW- After looking at the pic, I still think an easy out may get the screwdriver out.

I'd try drilling from the other end with a bit somewhat smaller than the stud until I either got close to the screwdriver (note the bit will probably grab the screwdriver and break if you reach it) or it runs off center (if it does, stop and look at it as a good way to get PB Blaster or similar in there deep...no big deal really there), then try driving it out with with a large drift punch or slightly smaller, hard bolt). Soak, soak, soak!

Or......... accurately center-punch a mark and try drilling out the bolt AND the screwdriver. Start with a small drill and work your way up. One of the biggest problems in drilling out broken fasteners is that they are usually steel and they break in aluminum. The steel is a lot harder than the aluminum so it is very easy to go off-center into the aluminum. Especially if you are not certain of the angle that the bolt is at in the aluminum. Staying centered in the bolt is critical. With the screwdriver in there you have another chance to get it right!

[Nick774]

Well I did exactly all of that with a LOT of soaking and torching and hammering. Nothing not even a budge. I have half of it drilled out to where I see the tip of the piece poking through. Im worn out, pissed off, and am running out of ideas.

[Andrew]

That's the time to take a break and revisit the problem after a few hours of something non-car related or preferably a good night's sleep. Heck, even a trip to the tool store to pick up more drill bits and a can of cutting oil can provide a much needed break.

The most valuable thing I've learned in nearly 16 years of DeLorean ownership is when to walk away from a project.

[Ron]

That's the time to take a break and revisit the problem after a few hours of something non-car related or preferably a good night's sleep. Heck, even a trip to the tool store to pick up more drill bits and a can of cutting oil can provide a much needed break.

The most valuable thing I've learned in nearly 16 years of DeLorean ownership is when to walk away from a project.
+1 (gives it time to soak too FWIW ;-)

[Bitsyncmaster]

I would use a Dremel with a right angle or flexible drive and grinding stones to remove the screwdriver first. You can then use a cutter in the Dremel to center the hole. Defiantly be careful using a drill bit after the screw driver is out that you don't break the bit off.

[dn010]

I've had to drill a few holes into the aluminum down to the bolt in the past - this allowed me to get some PB down in there and loosen things up. Add heat, a punch & hammer and it was out in no time.

EDIT: I drilled on the side of the mount into the aluminum down; Not into the aluminum from where the threads of the bolt would be down long ways (like the screwdriver looks)

[Nick774]

Thank you guys as always for the wise words. I stopped, ate a sandwich, stared at it for thirty minutes, attacked it, GOT IT OUT and replaced it with a brand new stud from DMCH. I wish that task on no man. The engine and trans are in and the build up begins!

26967

[Ron]

Cool beans :thumbup:

[ALEXAKOS]

Thank you guys as always for the wise words. I stopped, ate a sandwich, stared at it for thirty minutes, attacked it, GOT IT OUT and replaced it with a brand new stud from DMCH. I wish that task on no man. The engine and trans are in and the build up begins!

26967

What was in that sandwich... cause i got a stud to attack my self soon! :wrenchin:


What method did you use?
Congrats