So, I've got this older sports car I'm working on, and in the middle of a timing belt and water pump job, a corroded M6 stud snapped flush with the aluminum engine block. Most folks in my car forum advised against extractors, saying they could make things worse, and instead suggested welding a washer to the stud, then a nut to the washer. I know this is a common trick, but I'm struggling to make it work.
I hadn’t welded in 20+ years, so I picked up a Titanium Easy-Flux 125 from Harbor Freight, practiced on some scrap steel, and went to work. But after three days and about 30 attempts, I still can't get a washer to fuse to the stud. The weld pool looks molten, and everything seems to be getting plenty hot, but the washer always breaks loose.
The welder’s voltage/amperage range is 15.5V/30A to 20.3V/125A, with settings from A to J. I started at a medium setting and have gradually stepped it up—right now, I’m at about ¾ power on both voltage and wire speed, but I still don’t think I’m getting enough heat into the stud itself.
With an M6 fastener, the working area is tiny, so penetration is tricky. Would preheating the stud with a butane torch help, or is that risky with an aluminum block? Should I max out the welder settings, or is my technique more likely the issue? Any advice for making this work with flux-core? Appreciate any insights!
I hadn’t welded in 20+ years, so I picked up a Titanium Easy-Flux 125 from Harbor Freight, practiced on some scrap steel, and went to work. But after three days and about 30 attempts, I still can't get a washer to fuse to the stud. The weld pool looks molten, and everything seems to be getting plenty hot, but the washer always breaks loose.
The welder’s voltage/amperage range is 15.5V/30A to 20.3V/125A, with settings from A to J. I started at a medium setting and have gradually stepped it up—right now, I’m at about ¾ power on both voltage and wire speed, but I still don’t think I’m getting enough heat into the stud itself.
With an M6 fastener, the working area is tiny, so penetration is tricky. Would preheating the stud with a butane torch help, or is that risky with an aluminum block? Should I max out the welder settings, or is my technique more likely the issue? Any advice for making this work with flux-core? Appreciate any insights!