"1) Tig welded a washer and large nut onto the stud (probably 3 or four times). Tried both removing the stud while everything was red hot. The welds twisted off right at the stud. Then we allowed it to cool, tried turning a couple more times. The nut twisted off of the weld, but the weld stayed attached to the stud."
NO use for us "old timers" to try to talk to you young buckaroos, but if you want to be successful at broken stud/bolt removal, never EVER try to wrench on it while it's HOT.
Weld a washer (or whatever) to the broken stud, then let it cool to ambient temperature. Even weld a bit more to it and let it cool (again).
Only THEN, wrench on it.
The cycle of HOT and cool breaks the rust loose and gives you a fighting chance to remove the broken stud/bolt.
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Today's Featured Article - New Life for an Old Allis - by Tyler Woods. My friend Jon, has an old '39 Allis Chalmers B. He thought it a marginal tractor that had long since served its time. She smoked terribly and never had much power but he couldn't afford another so he was limping along with what he had. Jon's Allis has a small front loader and though it doesn't carry much, it serves his needs. It was the hard starting and low power that made him think it was time to replace the old girl. Jon called me to help him discover why his tractor wouldn't start
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