Cars & Racing | 3 January 2017Ford Flathead Rebuild: Removing Broken Studs Share article facebook twitter google pinterest Are you the type of backyard mechanic who is up for a challenge? How about tackling a rebuild and modifications on engines that are 60 to 80 years old? That’s exactly what many hot rodders and classic car restorers do when they dig into a Ford Flathead V-8, one of the most iconic engines of all-time. Of course a common problem one may encounter during this venture into an ancient engine block is a broken cylinder head stud. To figure out how to conquer this task we referenced the book How to Rebuild & Modify Ford Flathead V-8 Engines and found the answer in these step-by-step photos and captions. Removing Broken Studs Our tearless stud removal tools aren’t infallible. Some studs just won’t give up without a serious fight. Often as not these are studs that go all the way into the waterjacket, where they’ve collected hard deposits over the years that effectively cement the end of the stud to the block. In these cases the stud is almost certain to break, and there’s nothing to be done other than drill it out of the block. From dealing with countless broken studs over the decades, author Vern Tardel has developed a simple procedure that not only gets the stud out but in most cases does so without damaging the original threads in the block. The procedure requires a cast-iron cylinder head, an electric drill motor, 3?8-inch and 13?32-inch drills and drill bushings, a center punch, and locking pliers. Rather than describe it, let’s go right to step-by-step captioned pictures. A lucky break. This stud snapped at the deck (common) and did so with a level surface that permits a clean, center punch dead center. If the surface of the break is uneven, just carefully dress it with a hand-grinder so you can center punch it dead center. Use a sharp 1/4-inch drill to create a divot in the center of the stud. Don’t drill more than about 1?8-inch deep. This is your goal at this stage: a centered guide for the next step. Bolt a cylinder head in place—four bolts should be enough—place a 3?8-inch drill bushing in the bolt hole, grip it with locking pliers, and drill the center of the broken stud with a 3?8-inch drill. The 3?8-inch hole is nicely centered in the stud, all the way down thanks to the drill bushing that kept the drill concentric with the stud. Enlarge the hole in the stud with a 13?32-inch drill, taking care to keep it concentric with the hole. Use a 7?16 x 20 thread-chasing tap to finish the job. The remnants of the old stud come willingly out of the hole . . . . . . leaving a stud hole that’s almost as good as new. Buy from an Online Retailer The ultimate Ford flathead resource for hot rodders and restorers. The last commercially produced Ford Flathead V-8 was cast over 60 years ago. Simple by today’s high-tech standards, during its performance reign from the late ’30s through the mid ’50s, the flathead was unsurpassed for go-fast power on the cheap. It spawned the modern aftermarket speed-equipment industry and became a favorite of bootleggers, dry-lakes racers, dirt trackers, street racers, and a whole generation that just wanted fast cars. Whether you’re restoring a classic Ford, building a traditional hot rod, or creating a period custom car, you’ll want to get the most out of its vintage flathead V-8. In How to Rebuild & Modify Ford Flathead V-8 Engines, authors Mike Bishop and Vern Tardel, two of the most highly-regarded experts in hot rodding, give you the detailed and accurate information you need to build, restore, or just daydream about the engine that gave birth to hot rodding. Every aspect of buying, building, and owning a flathead V-8 engine is extensively covered. Go through the basics of selecting the right engine for the right project, building and rehabilitating engines, and final tuning. Diagrams and color photos bring these legendary engines to life for the hands-on hobbyist, collector, and aficionado. Keep it mild or build it wild, but either way, How to Rebuild & Modify Ford Flathead V-8 Engines will help ensure your flathead is delivering the power you need. Share article facebook twitter google pinterest If you have any comments on this article please contact us or get in touch via social media.