Broken Motor Stud (wire connection)

[Lochlin]

Guys,

I am right in the middle of a ScottyB upgrade on an early 90s shuttle. While removing the wire from the A1 terminal the stud broke. See pic. Yes, I was turning it the right way. The nuts on the other studs came off easily.

My initial repair thought is to grind the broken stud flush to the remaining nut then weld a 1/2 inch hex head bolt onto it, upside down. It's a bit tight in there but I think I can maneuver my mig around enough to make it work. If not I will pop the motor off and do it.

Still, I want to make sure there isn't an easier or better way. Has anyone else seen this and have any thoughts as to how to go about a repair?

Thanks in advance.

happened to me
http://www.buggiesgonewild.com/elect...ud-repair.html

[Lochlin]

Great minds think alike.

[kgsc]

If you can get the stud loose at the motor would a coupler and another bolt work?

[Lochlin]

Yeah, I considered that. That stud broke with a surprisingly small amount of force. If you look close at that pic you can see that that particular stud is a good bit more rusted than the others. I am fearful that monkeying with that stud further will only break it closer to the motor housing making a weld repair impossible.

[Epb]

I used a bolt extender from a sponsor, worked great then eventually sent for a bandit. You have enough threads to do so.

[Lochlin]

Yeah, there are plenty of threads under that remaining nut but I think I will have some trouble getting that nut off. I already gave it a couple of rotations to see if it would unlock but that only turned the entire stud. I don't want to go crazy on it and possibly pull the wire off inside. There isn't enough stud above the nut to even grip it let alone put an extender on it. The only way to get that nut off is probably to crack it. Might be just as easy to weld.

[JohnnieB]

Since it is the A1 stud and some brush sets come with new studs attached, you might luck out and solve the problem just by replacing the brushes.

[Lochlin]

That's good info, man. I actually got this thing done already.

Again, there's a chance that I pulled the brush wire off when I spun the stud when trying to get it off. If so replacing those bushes seems logical. I won't be able to test for a couple of days yet.

To be honest, I am planning on upgrading the motor sometime in the next few months anyways. If those wires got jazzed up I'll probably just go ahead and upgrade the motor now.