was coming away nicely then it snapped I think i already know the answer to fix this but i'm open to suggestions.
getting whats left of the threaded section won't be to hard. its getting a new threaded section back in there that's my biggest problem
Can you not just drop a bolt in from the hole above, not sure if you can get the mig in there though to put a blob of weld on
aa forgot it was a stud drill it out and cut a slot to get a bolt in weld in place then fold the bit you cut back and weld up
this is the only way i can think of, making a bigger hole and then welding it back up afterwards, something i wanted to avoid[:^(]
There is a strengthened plate inside the box section that holds the studs. Cut it open from the side to drop a high tensile bolt in after drilling it out. Then weld it into position and weld the box section closed. Gurds
yes its double skinned at that point so you would need to cut in front or behind the stud depending on witch one has sheared by about 1 1/2"
if it helps the mk1 brown haynes manual has the proper procedure, i could scan this in for you? iirc it involves drilling out, tap and use a bolt instead?
If you could. I'd like the most least intrusive method of repair for this. the idea of cutting it open and rewelding, doesn't appeal much. Though i did think this would be the only way to mend it.
http://sciroccoregisterforum.co.uk/faq/2010/02/22/repair-rear-beam-mounts-scirocco-mk1golf/ http://www.vwgolfmk1.org.uk/modules.php?name=Forums&file=viewtopic&p=557849
Checked it out last night, what you do is drill an 8mm hole in the exact centre of your stud, then tap it for a 10mm thread. then use a 40mm 10.9 grade bolt or you could use a stud instead threadlocked in place then it would look factory
do you flush whats left of the stud back for the tapping of an insert bolt? I don't get how you do your second suggeston though? other than doing a similar fashion to your first suggestion?
will have a look tonight to see if thats true, would be good, but i don't think its possible? Had fund the link on the rocco forum, but he doesn't show you how to fix the snapped stud, unless i've been blind? I would rather not have to cut and weld, as i don't have the facilities nor skills to do so in my garage.
yeah grind whats left flush then drill and tap. I just mean at the last step rather than using a bolt, fit a stud into the hole. that way it'll look more factory if ya gets me!
I just had a quick look at a mk1 lying here. Under the rear seat there does appear to be a hole covered in tape and sealer that may allow access for a bolt to be installed through. You may just need to drill out the broken stud to 10.5mm. This could allow a nut and bolt to be used to locate the rear axle bracket. No welding would be needed. Just someone holding the bolt from above whilst another tightened nut from underneath.
Ouch - hope you've got sharp drill bits. A 10.9 stud might take a while. If you can find the right grade of studding, I'd be tempted to drill and tap another stud straight in, or use a 10.9 allen bolt and chop the head off. With a bit of careful filing of the end, you should then be able to get the thread correct to get it in. I'd be nervous about using Time-Sert type inserts, but a helicoil should be strong enough, if you have to go oversize. If the thread is 10x1.5mm you need an 8.5mm drill bit. and appropriate thread tap.
