Broken studs
- Thread starter Barron
- Start date
- Joined
- Nov 25, 2012
- Points
- 178
- Location
- Newport, South Wales,UK
- Model of Z
- Z3 M43 1.8 (1999) and Z4 E85 2.5 (2003)
Think I remember someone on here used Rivnuts in place of the studs then use a suitable sized bolt to replace the broken stud into the Rivnut
As Tony says, I have had a couple of broken studs on both my 1.9 and the 2.8 project car. They are spot welded during the manufacture.
I have used rivnuts to fix them. By drilling a pilot hole (2mm) in the centre of the broken stud, then opening out to the rivnut size. Either 3 or 4 mm rivnuts are fine. Then you can either use a bolt or loctite in a short length of studding in and use a nut in the normal way ( with some copper grease).
( for studding, I just cut the head off a bolt and put the cut end into the rivnut. )
If you are doing the ones that hold the front wheel arches , then be aware that when drilling, the drill goes into the footwell under the carpet. And there are wires around that area. Only realised this when I was working on the project car and I had the carpet out. ( obviously a bit lucky when I first did it on the 1.9
Sorry cant find any pictures at the moment....but sure I did take a few.....I will try to locate them
I have used rivnuts to fix them. By drilling a pilot hole (2mm) in the centre of the broken stud, then opening out to the rivnut size. Either 3 or 4 mm rivnuts are fine. Then you can either use a bolt or loctite in a short length of studding in and use a nut in the normal way ( with some copper grease).
( for studding, I just cut the head off a bolt and put the cut end into the rivnut. )
If you are doing the ones that hold the front wheel arches , then be aware that when drilling, the drill goes into the footwell under the carpet. And there are wires around that area. Only realised this when I was working on the project car and I had the carpet out. ( obviously a bit lucky when I first did it on the 1.9
Sorry cant find any pictures at the moment....but sure I did take a few.....I will try to locate them
Thank you Malc.
Tony.
Tony.
Thanks mateAs Tony says, I have had a couple of broken studs on both my 1.9 and the 2.8 project car. They are spot welded during the manufacture.
I have used rivnuts to fix them. By drilling a pilot hole (2mm) in the centre of the broken stud, then opening out to the rivnut size. Either 3 or 4 mm rivnuts are fine. Then you can either use a bolt or loctite in a short length of studding in and use a nut in the normal way ( with some copper grease).
( for studding, I just cut the head off a bolt and put the cut end into the rivnut. )
If you are doing the ones that hold the front wheel arches , then be aware that when drilling, the drill goes into the footwell under the carpet. And there are wires around that area. Only realised this when I was working on the project car and I had the carpet out. ( obviously a bit lucky when I first did it on the 1.9
Sorry cant find any pictures at the moment....but sure I did take a few.....I will try to locate them
- Joined
- Nov 25, 2012
- Points
- 178
- Location
- Newport, South Wales,UK
- Model of Z
- Z3 M43 1.8 (1999) and Z4 E85 2.5 (2003)
Here are Mazzas pictures from his thread https://zroadster.org/threads/bognor-lean-to-project.44069/page-15
So onward to the broken studs at the back of the O/S wheel arch.
Cleaned the remnants of the studs off with a file, then centre popped the stud, and pilot hole and then. 6.5mm drill to give the rivnut a tight fit. ( had to gently tap it in )
Then using just a hex drive screw, a penny washer and a nut, tightened into the hole.
painted round the hole with red oxide before fixing it in……. This is when I got concerned as I could see daylight through the hole ???
It turns out that the other side of the panel is the footwell. And loads of wiring !!!!
Fortunately I didn’t hit anything but was close and may have only missed the loom as it’s been moved a bit when the carpet came out.
I pulled the loom away and drilled the hole for the second one and it went ok.
This is where they come through in the footwell, I had to clean away some of the insulation and painted them as well. When it’s dry I will make sure it’s well sealed before the carpet goes back.
The left hand one is close to the main thick positive cable and the right hand one is sitting in front of the main loom. ( which in the photo is the big one being held up in the air )
So worth remembering that there are cables there should anyone try this in the future!
So onward to the broken studs at the back of the O/S wheel arch.
Cleaned the remnants of the studs off with a file, then centre popped the stud, and pilot hole and then. 6.5mm drill to give the rivnut a tight fit. ( had to gently tap it in )
Then using just a hex drive screw, a penny washer and a nut, tightened into the hole.
painted round the hole with red oxide before fixing it in……. This is when I got concerned as I could see daylight through the hole ???
It turns out that the other side of the panel is the footwell. And loads of wiring !!!!
Fortunately I didn’t hit anything but was close and may have only missed the loom as it’s been moved a bit when the carpet came out.
I pulled the loom away and drilled the hole for the second one and it went ok.
This is where they come through in the footwell, I had to clean away some of the insulation and painted them as well. When it’s dry I will make sure it’s well sealed before the carpet goes back.
The left hand one is close to the main thick positive cable and the right hand one is sitting in front of the main loom. ( which in the photo is the big one being held up in the air )
So worth remembering that there are cables there should anyone try this in the future!
You can order threaded studs from any Volkswagen dealer, part number N90716103. Very easy to use and looks absolutely OEM. They need to be shortened a little bit after installation. Just meant as an alternative.
They look good.
Never seen those before…. Its a standard rivet gun fixing is it ?
Never seen those before…. Its a standard rivet gun fixing is it ?
Yep, only thing you should do is to use a small nut as a kind of a spacer, otherwise the thread can be damaged or deformed. Should look like this:
