1911 Ejector stud removal

[Curator]

My 1918 Remington 1911 .45ACP has sheared off the front ejector stud flush with the frame. I thought I could just drill and tap the stud and pull it from the blind hole in the frame but it is really hard! No drill I have will touch it. Any suggestions how I might remove the broken-off stud so I can replace the ejector?

 

[DnPRK]

Carbide drill or EDM

 

[dfariswheel]

One method I've used before is to use something like the SEARS screw remover that uses a drill-like bit to twist out broken screws.

Use a tool like that to try to get the stud to rotate just a little.
Then use a very thin screwdriver inserted into the stud hole to "worry" the stud upward enough to where you can grab it and pull it out.

Another way is to use a small carbide drill to drill a hole in the stud, then tap in a home-made SQUARE pin which you use as an extractor similar to a screw extractor.

 

[log man]

This isn't for the inexperienced hobbyist, but I've had very good luck at TIG welding on top of studs/screws broken off flush or below. Set machine at 15-25amps, and you can build straight up allow to cool completely and pull it out with pliers. The heat from welding also has the added benefit of breaking the bond it had in the hole due to expansion and contraction while welding and cooling.

LOG

 

[rcmodel]

A small carbide dental bur in a Dremel or drill press can be used to cut a hole down into it.

The heat from the grinding may be enough to melt loose the dried oil & grease that has glued it in place.

Be cautious with an Easy-Out, because if overdone when tapping it in, they will expand it into the hole and make it really really tight!

rcmodel

 

[Jim K]

If all else fails, you can use a steel cutting burr on a Dremel tool to cut into the frame below the hole and drive the broken part out with a long punch from below.

That blind hole was not one of JMB's better ideas, but in fairness, the ejector was supposed to be a semi-permanent part of the frame, not something to be changed every time some new gadget ejector came along.

Jim

 

[rcmodel]

My 1918 Remington 1911

In fairness to John Browning:

I doubt he ever invisioned a 1911 still being shot enough to break an ejector 90 years after it was made!

rcmodel

 

[Canuck-IL]

In fairness to John Browning:

I doubt he ever invisioned a 1911 still being shot enough to break an ejector 90 years after it was made!

+1 - it's entirely possible that at the time JMB designed the 1911, he just didn't know that he and the gun would become legendary!
/Bryan

 

[Jim K]

Right on! All he wanted to do was put out something that would satisfy those damned picky army officers and make a bunch of money.

Jim