How much torque are you putting through those studs?!!!

 

JB Weld. It can stand up to heat cycles, moisture, etc.

 

OK I will try some JB Weld, thanks. I spoke with the dealer technician and they don't repair broken studs. Pedro's Garage recommends using a large headed screw. Not sure I want to drill holes in the under tray.

 

These are the studs on the floorplan I presume.

JB Weld might work to attach a large bolt and washer to the floorpan of the car, but probably will not. If you wanted to try you would first have to grind down the remaining stud (which is welded to the floorpan) first. Once you are that far, might as well either spot weld a new stud on, paint and rustproof, or go with a nutsert into the floorpan (depends on what is above this stud).

 

If you're breaking studs off, you're using too much torque. The plastic nuts are only supposed to be torqued to about 10-15 inch-pounds, which is just barely snug when tightend by hand.

I had a stud pull out on my old car. I fixed it by welding the stud to a fender washer, and then JB Weld'ing the stud/washer to the original location. Just make sure that you remove all the undercoating and paint on the body, so that the metal surfaces are bare and clean. Also, you may need to user a hammer to flatten the area where the stud came out, since there will probably be a raised lip. Then, once the glue has hardened (get the normal JB Weld, which takes 24 hours, not the 5-min stuff), paint over the area with a good rust-proofing paint.

Done properly, a repair like this should last the life of the car. Mine was still going strong nearly two years later when I traded it in.

 

BillC,
Not having access to welding equipment, I am going to try this commercial equivalent to your solution from ClickBond.

. I've asked the company if they have this product with a T-5 stud. In the meantime I've ordered some ClickBond 3200 with 10-24 thread.

Rob

 

Looks like a good a shot as you are going to have with epoxy. Post the part number, I might give this a try as well.

 

The parts I bought are ClickBond CS125-1024-16CR Adhesive Bonded Studs, ABS APPROVED from ElectricalHub, their stock number 68-0115 with a 10-24 1" stud and 1 1/4" diameter base in all stainless. ElectricalHub has a minimum buy of $35 so you will have a lifetime supply. I've asked ClickBond if they can supply this product with a T-5 stud.

 

I posted an article here on installing the ClickBond studs

ClickBond CS125-1024-CR - Articles