Welding Tips and Tricks

I have an issue on a 2004 Ford Truck with a broken spark plug inside an aluminum cylinder head.

We are a professional repair facility and have removed lots of these. We have all the special tools.

This particular one, when attempting to push the porcelain down in order to install the tool, it appears as though the metal electrode cup was actually pushed down instead of the porcelain moving inside the metal cup.

We are at the point of having to pull the cylinder head unless I can manufacture something.

Here is my thought. Is it possible to use my TIG/Stick machine to make some type of a spot welder.

If I can use some type of 3/8" size rod that will fit the end of the remaining cup that is stuck, I can insulate it and drop it 5" inside this aluminum hole to touch the cup.

Then if I can spot weld it in place somehow, I should be able to pull the cup out of the hole.

What are your thoughts? This cup is non magnetic, probably stainless, but I don't know.

There is a special rod for tacking onto bolts that are broken off. Can’t remember what it’s called but there’s been some pictures posted on here before.

Poland308 wrote:There is a special rod for tacking onto bolts that are broken off. Can’t remember what it’s called but there’s been some pictures posted on here before.

This stuff


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Could you braze an extension onto a spiral easy out? Use that to get plug end out of the head.

Your best bet would probably be the TIG. fire it up and weld stuck a piece of rod or something to the tungsten. Then put it to HF start and lower it into the hole and when you are close, pull the trigger and it'll jump off the rod, then push it into the plug tip and that should do it, then it's stuck to it, pull it out and voila.