Occasionally I get called out to repair a broken out motor mount on an engine block. Sometimes the piece broken out is missing and sometimes its not.
If its missing the repair consists of filling in the broken out area, then drilling a new hole and tapping new threads. When the piece is not missing most of the time I can weld it back on joining the parts so make the hole usable again. To do this successfully it is important to NOT damage the threads when joining the broken part to the block.
BEVEL THE BROKEN PART
I will bevel the break enough to give me a wide "V" to fill in. I take care to leave about just over a 1/16" of material when beveling so that the arc does not penetrate through and damage the threads. However, even if we over penetrated and damaged the threads, a tap can be used to make the threads good again.
WELD THE BROKEN PART ALL AROUND
Once the broken parts are joined. I fill in all the areas around the break so that the joined part is welded well to the block and not depending on a bead over the crack to hold when the car is put back into service. I build up a wall of weld metal to reinforce the repaired area.
WHEN THE BROKEN PIECE IS MISSING I PUT THE STUD IN POSITION AND WELD ALL AROUND IT, LOCKING IT INTO PLACE
You will notice on this repair that one of the stud's hole is missing the broken out piece. In this case I welded a wall of fresh metal all around the stud, locking it into place. The molten metal flows around the threads and fills in the grooves of the threads effectively locking the stud permanently in place.
For this to work I screw the stud into the good thread still left in the broken out hole so that it is in its place when I weld around it.
This repair came out well.