Which process for me?

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I have never really welded.  I just bought one of those Lincoln Power Mig 210 machines but I did not get the TIG setup or the gas setup for MIG welding yet.  So, right now I can either stick weld or do flux core wire feed.  I am trying to figure out which process to use for a particular project I have.  I am willing to pick up the MIG bottle if that is the best way to go, but I would rather not have to get the TIG setup at this time.  So, MIG with gas, flux core, and stick are possibilities, and I can't weld to save my soul.So here's the problem - 65 GTO clutch ball stud is broken off in the block, recessed maybe a millimeter from flush.  The plan is to lay underneath the car and try to weld a small nut to the remainder of the stud.  I do not think it is frozen from rust or anything, it just broke because of engine movement relative to the frame.I have a couple  of concerns:(1) Fire.  I was thinking I'd lay a welding blanket over the engine and try to clean any oil and such away from the work area.  Does wire feed create less sparks/smaller arc than stick?(2) Hot stuff dripping down on me.  The ball stud sticks out of the block horizontally so the weld surface faces vertically.(3) How do I get the nut to stay on the stud while I weld it?  Thoughts?  Basically what I plan to do is take your input on which process to use, practice with that process for a bit by welding nuts to some scrap metal, and then give it a go.  Thanks!
Reply:well, if the stud is not frozen in the block, you can remove it several ways that doesnt bring fire into the equation , 1st, use a hammer and sharp pointed punch and tap counter clockwise along the edge, till she backs out, 2nd, drill a hole in the middle of it and use easy out screw extractors..Of all the things I lost I miss my mind the most...I know just enough about everything to be dangerous......You cant cure stupid..only kill it...
Reply:I tried drilling it and it is really, really hard.  I even took the other broken half out of the Z bar and tried drilling it in a vice with both cobalt and titanium bits and still no luck.  The surface is pretty smooth and it is pretty tight in there so I am not sure I can get in there to turn it with a hammer and punch.  The MIG gun should fit though.
Reply:Have you even practice laying down any beads yet with the new machine? If it broke off from vibration it shouldn't be very tight in there. Don't weld the bolt to the block
Reply:Nope, haven't used the new machine yet.  I am trying to decide which process to practice.
Reply:It will be much easier for you to see if you weld a washer on the stud first.Then a nut to the washer.This is the way I do it every time for broken, rusted bolts - and so far I've only used a mig for this operation (and stick once just cause it was handy and already laying there).I'm not against using my tig, just have always used the mig for it.If you are not successful, it will likely be way less stress to just pull the motor - great excuse to clean it up and put in new gaskets and stuff too. Last edited by MinnesotaDave; 01-07-2015 at 04:07 PM.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:For this tig or mig. I'd start with tig. You might wanna smack the bolt with a punch and a bfh real good first to shock the threads. If the bolt is small probably mig tho
Reply:what size bolt? diameterOf all the things I lost I miss my mind the most...I know just enough about everything to be dangerous......You cant cure stupid..only kill it...
Reply:The stud is big, guessing 1/2.  I haven't looked at it for awhile.  What does the washer do?  I can't picture how this helps but I have read that suggestion somewhere.  Sounds like MIG is the way to go.  Any reason not to use the flux core stuff or do I need to get the shielding gas setup for this?
Reply:Because its thinner then a nut and easier to weld.
Reply:you can use flux core, the washer lets you see the end of the broken bolt, say the washer is only 1/8 inch thick, where a nut my be 3/8 thick , you wont see clearly down the hole in the nut, once the washer is welded to the broken bolt you will have a much bigger area to weld the nut on and not damage any threads in the block..Of all the things I lost I miss my mind the most...I know just enough about everything to be dangerous......You cant cure stupid..only kill it...
Reply:Originally Posted by roadkillbobbyou can use flux core, the washer lets you see the end of the broken bolt, say the washer is only 1/8 inch thick, where a nut my be 3/8 thick , you wont see clearly down the hole in the nut, once the washer is welded to the broken bolt you will have a much bigger area to weld the nut on and not damage any threads in the block..
Reply:When you do go under the car: Some one up top with a Fire Ext.Ear plugs (keeps the hot BBs outta da ears), long sleeves, head cap. and of course weldin' hood, gloves etc.Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:I can do everything except the someone else with the fire extinguisher.  I will have one handy and be as careful as I can.  I guess I may wind up winning a Darwin award but what the heck I've never really won anything before.
Reply:A good welder told me once he doesn't like welding on cars or motorcycles because he has had a arc strike in the motor on a bearing before. Bike came back in and the bearing was toast beacuse there was a arc strike on it. I always been sketch on welding on cars since. Anyone experience that or heard of it?
Reply:Originally Posted by motolife313A good welder told me once he doesn't like welding on cars or motorcycles because he has had a arc strike in the motor on a bearing before. Bike came back in and the bearing was toast beacuse there was a arc strike on it. I always been sketch on welding on cars since. Anyone experience that or heard of it?
Reply:Originally Posted by i82muchI can do everything except the someone else with the fire extinguisher.  I will have one handy and be as careful as I can.  I guess I may wind up winning a Darwin award but what the heck I've never really won anything before.
Reply:When I do I try to keep the ground within inches like your saying keep it close
Reply:Originally Posted by storemanSo...you spent $1,000 on a machine you haven't even tried yet.... in order to save a couple hundred... and have no indicated plans for the machine once this "project" is done....Yes you may qualify for a Darwin, especially if you don't even have a friend to standby with the fire extinguisher!
Reply:Originally Posted by motolife313Way to make him feel all warm and fuzzy inside. It's not like the car is going to be  engaulfed in huge flames right away. It's gona take what 7 seconds to weld the washer then he's all eyes on everything
Reply:lol. Are you speaking from personal Experience?
Reply:He could be the next ztfab, who knows
Reply:Originally Posted by storemanSo...you spent $1,000 on a machine you haven't even tried yet.... in order to save a couple hundred... and have no indicated plans for the machine once this "project" is done....Yes you may qualify for a Darwin, especially if you don't even have a friend to standby with the fire extinguisher!
Reply:Originally Posted by storemanSounds like you should be there holding the fire extinguisher for him.  While he is under the car being "engaulfed" with the fire extinguisher "handy", I'm sure he will be calm enough to unass that position, find the extinguisher, spray himself and the vehicle down.  Not to mention the new Lincoln welder, which will likely be returned under 30/60 day satisfaction guaranty.    Whole idea sounds idiotic but don't take it personally, either you or the OP.   Good night.  I ramble too much.
Reply:I've talked to plenty of guys that weld on their cars all the time.  I just keep running into situations where I need a little bracket or something, fix a trailer, whatever and wind up going through great lengths to get someone else to do it.  I've wanted a welder for a long time and this just seemed like the time to break down and get one.  From what I gather the Lincoln I picked up is versatile enough for anything I would want to do.Originally Posted by i82muchI've talked to plenty of guys that weld on their cars all the time.  I just keep running into situations where I need a little bracket or something, fix a trailer, whatever and wind up going through great lengths to get someone else to do it.  I've wanted a welder for a long time and this just seemed like the time to break down and get one.  From what I gather the Lincoln I picked up is versatile enough for anything I would want to do.
Reply:you will get plenty of use out of it...everyone comes out of the wood work when they find out you can weld...Of all the things I lost I miss my mind the most...I know just enough about everything to be dangerous......You cant cure stupid..only kill it...
Reply:Originally Posted by motolife313 lol. Are you speaking from personal Experience?
Reply:Originally Posted by motolife313He could be the next ztfab, who knows
Reply:Originally Posted by i82muchMight want to work on your spelling too ... http://dictionary.reference.com/browse/engulf
Reply:Originally Posted by storemanIf you read the thread, I was quoting Motolife's spelling.
Reply:Had an '82 Chevy6.2 diesel in which the starters support bracket bolt kept coming out (of the block) & then eventually one of the 2 mounting bolts would break off a half inch or more up in the block. Drilled a hole through a piece of brass rod that fit in the hole (to protect the threads). What would happen was as I drilled, the pieceof remaining bolt would dislodge & get spun to the bottom of the hole/threads. It would really get jammed in tight!Finally, I bought a set of 'backwards' drills from Harbor Freight. That did the trick.Also, welding on newer cars with ALL the electronics in them could/can do MAJOR damage, I would think long & hard before welding on one. On one job we had a Hitachi 1000 excavator (the mighty Hitachi, we are not worthy) which had an electronic system installed whic really simplified the operators job, he had a screen which showed rotation angle of the bucket, depth, lines for grade, undercut, line for bottom of slope, etc. A 'Topcon' unit, nice. (I was grade-checking, but used it a little).The mechanics needed to weld on the machine & I told them what the Topcon people told me: DONT!! Actually, to unplug ALL plugs from ALL boxes for sure, or it will be f****d up.Well, they wouldnt give us the time to unplug, & did some $60,000 damages. This is why I said about the welding.-c-(Oh yes, what I had to do when I found out about the broken stud was: the remaining stud would stretch enough that the start/fly gears no longer meshed. I got out the tire jack & jacked up the starter till the truck moved {slightly!}, start truck, remove jack & go home & fix, This usually happened about 6 miles from a paved road!)Last edited by cornemuse; 01-09-2015 at 01:49 PM.Reason: feng shuiWhat is the sound of one knee jerking?
Reply:Originally Posted by cornemuseHad an '82 Chevy6.2 diesel in which the starters support bracket bolt kept coming out (of the block) & then eventually one of the 2 mounting bolts would break off a half inch or more up in the block. Drilled a hole through a piece of brass rod that fit in the hole (to protect the threads). What would happen was as I drilled, the pieceof remaining bolt would dislodge & get spun to the bottom of the hole/threads. It would really get jammed in tight!Finally, I bought a set of 'backwards' drills from Harbor Freight. That did the trick.Also, welding on newer cars with ALL the electronics in them could/can do MAJOR damage, I would think long & hard before welding on one. On one job we had a Hitachi 1000 excavator (the mighty Hitachi, we are not worthy) which had an electronic system installed whic really simplified the operators job, he had a screen which showed rotation angle of the bucket, depth, lines for grade, undercut, line for bottom of slope, etc. A 'Topcon' unit, nice. (I was grade-checking, but used it a little).The mechanics needed to weld on the machine & I told them what the Topcon people told me: DONT!! Actually, to unplug ALL plugs from ALL boxes for sure, or it will be f****d up.Well, they wouldnt give us the time to unplug, & did some $60,000 damages. This is why I said about the welding.-c-(Oh yes, what I had to do when I found out about the broken stud was: the remaining stud would stretch enough that the start/fly gears no longer meshed. I got out the tire jack & jacked up the starter till the truck moved {slightly!}, start truck, remove jack & go home & fix, This usually happened about 6 miles from a paved road!)
Reply:the only way your gona learn is by doing it yourself..just take your time and be safe...if you can get the car up on a lift so you have room to work, even the better...Of all the things I lost I miss my mind the most...I know just enough about everything to be dangerous......You cant cure stupid..only kill it...