Stud Removal With a Welding Rod

Welding Rod Rescue

• To remove a stud with a welder, use a flux-coated steel welding rod that’s 1/8 inch in diameter and set your welder at 70 amps for studs up to 3/8 inch in diameter. For larger studs up to 3/4 inch, set at 100 amps. For big studs up to 2 inches, set at around 130 amps. If the stud is embedded in a flat horizontal surface, hold the rod perpendicular to the surface of the part and bring it to the center of the broken stud. Strike an arc, being careful to keep the arc on the broken stud. Avoid tilting the rod as this will send the arc to the threads in the hole. Move the rod slightly as you build up a column of weld metal.

Weld a Nut

• Keep on welding until you reach the surface. The flux that boils off the rod will keep the weld metal away from the threaded walls of the hole. If the broken stud already is flush with the surface, weld a bead of metal on top of it. Clean the weld metal, place a washer on it and then a nut that’s about equal to the diameter of the broken stud. Weld the nut to the metal column or bead, completely filling the hole in the nut with weld metal. Allow the piece to cool to room temperature. Once the piece is cool, use a hand wrench to turn the stud out of the hole. When the broken stud is out, use the proper size tap to clean up the threads and install a new stud.

Horizontal Studs

• If the stud is embedded horizontally in a vertical surface, you’ll use a slightly different technique. If the stud is down in a hole, line the hole with a copper tube to protect the threads from sagging weld metal. Build up the weld metal using short welding bursts rather than a continuous weld, keeping the rod perpendicular to the surface. If molten slag runs out of the hole, stop and let the work area cool. Once it’s cool, resume building up weld metal. Once you are at the surface, weld a nut onto the weld metal and turn out the stud.

Overhead Studs

• If the broken stud is embedded overhead, you still may be able to get it out. Reduce your welder’s amperage by about 10 percent to reduce falling spatter. Use a series of short bursts to build up weld metal, then weld a nut onto the metal column and turn out the stud. Some companies market welding rods they claim are designed specifically for removing broken studs. If you use these specialty rods, follow the manufacturer’s directions regarding amperage settings and welding techniques.