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Homemade Broken Screw Removal Punches


BUILDER:
bborr01 on bbs.homeshopmachinist.net
DESCRIPTION:
Homemade broken screw removal punches fabricated from drill rod or round stock. Punch tips are ground down from dull taps.
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Dec 14, 2016 8:30 PM
Anonymous
I used to be a machinist at a Ford Truck dealership and we would get cylinder heads in the machine shop where mechanics had used and air wrench on the exhaust manifold studs which resulted in breaking the studs off even with the cylinder head. The easiest way to get those studs out was to hold a cutting torch on the stud until it was nearly white hot. Once that was the case, just a touch on the handle that delivered extra oxygen ,normally used for cutting, would blow out the stud and leave a clean hole to run a tap in to clean it up. The studs had been located in a place where there was a lot of heat and they were all but welded in to the cylinder head. I did use punches like you show to begin with and it would take a lot of time to drill a hole in the middle of the stud and increase the drill size until you reached the root of the threads then pick the rest out with a punch like you are showing. The punches work for sure but there are other ways to get a broken bolt out just like there are more than on way to skin a cat.
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DIY Broken Screw Removal Punches - comment on how to build a Broken Screw Removal Punches - 2 comments
Anonymous says:
Dec 14, 2016 8:30 PM
I used to be a machinist at a Ford Truck dealership and we would get cylinder heads in the machine shop where mechanics had used and air wrench on the exhaust manifold studs which resulted in breaking the studs off even with the cylinder head. The easiest way to get those studs out was to hold a cutting torch on the stud until it was nearly white hot. Once that was the case, just a touch on the handle that delivered extra oxygen ,normally used for cutting, would blow out the stud and leave a clean hole to run a tap in to clean it up. The studs had been located in a place where there was a lot of heat and they were all but welded in to the cylinder head. I did use punches like you show to begin with and it would take a lot of time to drill a hole in the middle of the stud and increase the drill size until you reached the root of the threads then pick the rest out with a punch like you are showing. The punches work for sure but there are other ways to get a broken bolt out just like there are more than on way to skin a cat.

daveward says:
Jan 04, 2014 11:40 PM
Really?  Is drill rod the same material as a drill?

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