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I was trying to get a cam gear cap/bolt thing off a 2000 Volvo S80 2.9l and stripped the torx pattern out of a bolt. I'd guess it's around 1-1/2" in diameter, and this is what it looks like:

volvo cam gear cap

I have tried other things like using JB Weld to hold a torx bit in and cutting a slot in the cap and trying to use a hammer and screwdriver to turn it but nothing has worked so far. Besides drilling it out, the only other thing I can think of is welding a nut to it (don't have enough room to fit a normal sized drill and bit in there anyway).

I've only ever tack welded for a job I had and they set everything up for me. I'm not sure what amperage or the kind of sticks I need. I definitely don't want to blow through the cap, or weld it to what's behind it. It needs a strong weld, because it doesn't want to come loose for some reason.

What kind of amperage and sticks needed to weld a nut to a stripped cap/bolt?

Can someone provide me with some direction on how to get this done successfully?

DucatiKiller
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user43704
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1 Answers1

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Mig welder is what I use for welding nuts to broken fasteners, 100-120 amps or better should do it on that size bolt. Stick welder about the same amps, use a 6013 rod, 6011 for better penetration if needed.

My amp recommendations are general in nature, you want the most heat and penetration you can get quickly without melting the nut completely.

Moab
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