Weld a nut to a broken bolt

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My son says Its my answer to everything.2000 Cheby 5.3 V8 Aluminum heads.  Last manifold broken off below the surface of the head.I used Alstate 275 at 71 amps I built a little tit on it, then another one,..... Till I could put a 3/8" nut on it.  I welded the tit to the nut and took it out after it cooled.  The one next to it only had the head broken off, so I took that one out too.Through this hole. My lucky day.  I made good $ on it too.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:That there is pretty much the only reason my truck doesn't have headers.Here learning to turn down the Suck...
Reply:Originally Posted by Atomik777That there is pretty much the only reason my truck doesn't have headers.
Reply:Glad you made some money on it. It used to be I wouldn't let a customer hang around while I did that repair. I used to sell the value, not the time. Good Job. My Kinda JobLincoln Ranger 8                        Lincoln 175                          Drill pressLincoln 225 mig                            Plasma                              8 ft brake        52" jump shear
Reply:I have certainly done my share of those of heavy construction & farm equipment as well as cars & trucks! Some go easy and others!!!!!! Co-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.&  2 Hypertherm HPR260's Plasma CutterSorry I had a bad stroke but now I am back.
Reply:The manifold was stock. The truck sits a lot. I gave him the price before the job.  A regular auto shop would have taken off the head and probably exchanged it for a rebuilt.  I would not do a job like that in front of a customer.... Ever...And sure there are days the floor is covered with nuts from failed attempts.David Last edited by David R; 06-12-2009 at 08:58 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:LOL yep some do some don't..    When I used stick rod for that I used tiny stainless rod.My most recent bolt in aluminum, weld a nut on it deal, was for a neighbor in one of those pesky lawn mower deck hubs.    I didn't think the hub was worth removing the 2 broken bolts. Anyway welded on 2 nuts, Let it cool a bit then applied a bit of heat to the Ally hub.   Got them to move slightly & gave it back to him.   told him to soak them with penitrant & work them out slowly.   also told him if you twist one off now, go buty a new hub.    No Charge.....IF IT WORKS, DON'T FIX IT2 Lincoln CV-300 / LN-7 GMALinde-VI 253,400 & 450 w/MIG35 feedersCNC Table with Oxweld O/A & Hypertherm 1250G3Lincoln Ranger GXT 250Hobart-MicroWire 300ESAB Heliarc 161ESAB-Mobilemaster 2 CC/CV Feeders& more
Reply:ive put a washer over a broken bolt and plug welded the washer to the bolt then welded a nut to the washer. that works very well too.
Reply:Originally Posted by David RThe manifold was stock. The truck sits a lot. I gave him the price before the job.  A regular auto shop would have taken off the head and probably exchanged it for a rebuilt.  I would not do a job like that in front of a customer.... Ever...And sure there are days the floor is covered with nuts from failed attempts.David
Reply:Originally Posted by El_Lloydeoive put a washer over a broken bolt and plug welded the washer to the bolt then welded a nut to the washer. that works very well too.
Reply:it just allows for more weld to be put around the nut. ive also taken oversized nuts and plug welded them to the broken bolt. let it cool good though before you get to crankin on it!
Reply:Originally Posted by El_Lloydeoit just allows for more weld to be put around the nut. ive also taken oversized nuts and plug welded them to the broken bolt. let it cool good though before you get to crankin on it!