For anyone following this. The 90 amp mig welder from harbor freight worked beautifully. I set the min/max switch to max. and a feed speed of about 5-6 (out of 9).

I bought plain uncoated grade 2 steel 5/16" washers and 1/2" Nuts. I bought them from mcmaster.com you can sort by size, finish type, etc

minimum order was 100 but with 100 washers and 100 nuts order was only like $12, and now I got extras, which I keep in the house since they are uncoated steel you dont want them rusting out in the garage/shed.

you want uncoated steel because the coating release toxic gases if you weld them, also you want low grade steel because it is more mild and welds much easier, especially for this little 90 amp mig welder.

I held the washer with a pair of channel locks over the snapped off stud, and with the other hand welded it on, same with the nut over the washer.

The first try I had the mig on low power instead of max. so the first washer nut that I welded on pretty much fell right off soon as I put a wrench on it.

So I took a punch and tapped on the snapped off stud some to help break it loose and then I proceeded to weld on the second washer and nut but on max power this time.

worked like a charm! the broken stud came right out.

Also this was my first time using a mig welder, and I hadn't used a stick welder for over 14 years back when I was in High School. It honestly was not difficult long as you take your time and have some patience. I would recommend this to anyone that has snapped a bolt off in the block!

The coolest part was the bolt was out in less than 15 minutes! would have been less than 8 minutes if the first attempt hadn't broken off.

 

Grats. Was worried it might not ever come out

 

i had one break off on me in my 88 gt i used a titanium bit and a easyout kit from advance auto took about 10 mins and cost 8 bucks but i been working on cars around 15 years now but good luck with what way you choose and let us know how it goes

 

sry guys thought i was on the last page when i replied i guess not

 

yeah what I was saying on my last post, its a done deal, I got it out using the mig welder. I have used quality bits and easyouts, and I have probably snapped the easy outs off atleast half the times I used them. Quality drill bits + an easy out will cost a lot more than 8 bucks unless you happen to have some quality drill bits already.

Having tried easy outs before, and having snapped them off, and left with a mess where you generally end up having to drill it out and retap to a larger size, I didnt wanna go down that road! Thats why I tried the welder way, and from everything Ive read the success rate is higher using the mig welder method than it is using the easy out method.