The Shock Unlock didn't work and they've been drenched with WD40. I've drilled one stud down to the blind end so it's had WD40 from both ends. I've heated them and frozen them. I've used left hand thread extractor bits. I bought a set of stud extractors that slip over the stud and grip as you turn but the broken end was too short.
Quote:
Originally Posted by DarrenSV650S
If you are going to drill and tap it. Try the original size first. That should clear out the broken stud and leave you with the original thread
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I've thought about this one but I've decided it would only work if I was able to start the tap in the line of the original thread. The chances of doing this are poor and if I get it wrong I'll be cutting out at least part of the original thread leaving a very much weaker fixing. I can imagine having spent ages on my back carefully tapping it out and then stripping the weakened thread as I torgue the new studs back up.
I'm tending strongly to the helicoil. Need to think of a way to fix the line of the drill bit so that the new studs are in the right position and square. I think it will wander if I just hold the drill and guess, even with a centre punch on the stud I haven't drilled yet.
I like the stainless studs suggestion - if I ever get that far!
Thanks again, all.