Re: HELP! DAMN! HELP! BROKEN STUD!

[drew <drew@dyermaker.cs.uoguelph.ca>]

I've got this problem on the 84 GLI that's sitting in the back shed (my
ORIGINAL project car...)  I've had opportunity to investigate what's
needed to repair the broken stud on a multitude of parts cars.

The two studs are actually 'bolts' that appear to be press fit (possibly
welded?) into a reinforced plate that's a bit larger than the area covered
by the axle.  The bolts do not have a hex head, but rather a flat round
head.

To access this area you have to cut a hole in the running board/inner rear
fenderwell area.  The actual location of the cut varies on the A1 chassis
from 2dr to 4dr and Scirocco (I expect) but should be roughly the same.
Unfortunately the reinforcing plate and bolt heads are inside the
rocker/fender well, so access will be limited (depending on the size of
the hole you want to cut.)

I believe I can achieve a good effect by nibbling a small hole a couple of
inches square, drilling the old stud out from below, then installing a
good hard bolt from above and the either one of the following:

a) leaving an access plate (using screws) so that I can but a socket on
the bolt for future axle removal
b) cut a large enough hole to get the mig down in there to weld the bolt
to the reinforcing plate
c) weld the bolt from underneat then grind the weld to clear the hole in
the axle support.

It's going to be a few years yet before I get back to that project car
(since I've found my Scirocco, it may be even longer...!) so I won't be
writing a tech procedure any time soon, but I believe it shouldn't be a
really big deal (if you call cutting holes in your car not a big deal...)

BTW, the poster that said they drilled and tapped for a smaller bolt -
sounds like a reasonable solution to me - especially if a good hard bolt
was used.  Perhaps an even better idea would be to use a fine thread pitch
bolt?

Drew

On Mon, 6 Mar 2000, Chris DeLong wrote:

> 
> I know this sounds like a long shot but what about removing the carpet and 
> insulation above the broken bolt and welding a plate about 2" X 2" to the 
> floor and drilling a hole and putting same size/strength bolt through that 
> hole and welding it to the plate. Just a thought...
> 
> Chris DeLong
> ICQ#45030867
> Seattle, WA USA
> '80 16V Rag
> '80 Rocco (new!)
> '65 Bus (ugly, but good for campin' W/toaster oven)
> '82 GLI (now with a happy shaved, solenoid operated trunk)
> '80 'Vert
> '61 17 Window
> '78 Scirocco
> 
> 
> ______________________________________________________
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> 

Drew MacPherson, Network Analyst, University of Guelph

drew@dyermaker.cs.uoguelph.ca           |  visit the Massey-Harris page:
http://dyermaker.cs.uoguelph.ca/~drew   |  http://m-h.cs.uoguelph.ca


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