Here is another repair I have been working on. A broken stud on a 69 front turn signal/parking light housing. Over the years the nuts became rusted on to the stud and when you go to take it off, the stud breaks very short. The stud is not a hardened or plated part. It was electro welded to base prior to cad-plating and they need to carry the ground to the bulbs.
Well, here is how I fixed mine. Your mileage may vary
Drill out the stud, do not worry about using a large drill size. the hole in the base is bigger then the stud. I did a pilot hole, then went up in drill sizes until the stud was mostly gone. Then I grind the inside enough to thin it to allow it to be punched it out.
For the replacement stud, I took a 1/4 x 20 slotted bolt 1.5" long I had in my parts bin. Put them into my drill press and used a grinder to flatten the head.
Here is the before and after on the bolt
Then I made a bracket to hold the new stud in for welding
You have to clean the plating off the back of stud for a good weld. Just used my press and dremel again
Welded it up. Be careful not to weld the bolt threads too high. The nut needs to go down even with the base to fit properly.
Then grind the excess with a dremel carbide bit to clean it up
Next I put a die on the stud before cutting it to length. Bevel the top of the stud too to match original
Remove die to clean up threads and bead blast to finish it off
Then test fit it!
Well this was my first try, things I need to improve on
keep the weld lower (I had to clean up the threads to get it to mount)
I cut it 1 thread too tall and did not bevel end enough (fixed it, grinded more off, then put the bevel back)
Well, here is how I fixed mine. Your mileage may vary
Drill out the stud, do not worry about using a large drill size. the hole in the base is bigger then the stud. I did a pilot hole, then went up in drill sizes until the stud was mostly gone. Then I grind the inside enough to thin it to allow it to be punched it out.
For the replacement stud, I took a 1/4 x 20 slotted bolt 1.5" long I had in my parts bin. Put them into my drill press and used a grinder to flatten the head.
Here is the before and after on the bolt
Then I made a bracket to hold the new stud in for welding
You have to clean the plating off the back of stud for a good weld. Just used my press and dremel again
Welded it up. Be careful not to weld the bolt threads too high. The nut needs to go down even with the base to fit properly.
Then grind the excess with a dremel carbide bit to clean it up
Next I put a die on the stud before cutting it to length. Bevel the top of the stud too to match original
Remove die to clean up threads and bead blast to finish it off
Then test fit it!
Well this was my first try, things I need to improve on
keep the weld lower (I had to clean up the threads to get it to mount)
I cut it 1 thread too tall and did not bevel end enough (fixed it, grinded more off, then put the bevel back)