Eagle 865 Stud Puller Welding Rod | High-Strength Low-Heat Electrode

Eagle 865 is recommended for:

Broken bolt and stud removal
Joining dissimilar steels
Low-alloy steels
High-alloy steels
Tool steels
Carbon steels
Shaft rebuilding
Forging dies
Hot shearing blades
Dies and punches
Conveyor chains
Debarker knives

AC or DC Reverse [+] Polarity

Clean the weld area thoroughly. For carbon steels, preheat to approximately 400°F where appropriate. Maintain a short arc and use stringer beads to help prevent overheating. Allow the deposit to cool before removing slag.

Broken Bolt Removal

Degrease the broken bolt and surrounding area.
Using Eagle 865, strike the arc in the centre of the broken bolt and build the weld deposit upward. The Eagle procedure explains that the molten metal adheres inside the broken bolt while flux helps protect the surrounding threads.
Once sufficient weld metal has been built up, position a hex nut over the broken bolt and weld the nut in place. The heat from welding also helps loosen the broken fastener before removal.

Eagle 865 is a high-strength, low-heat repair electrode engineered for difficult joining and build-up applications.

It is heat resistant, corrosion resistant, and designed to produce high-strength weld deposits while limiting heat input into the base material.

Why Eagle 865?

Broken-bolt specialist — ideal for removing broken studs and bolts, including fasteners broken below the surface.
High-strength deposit — approximately 120,000 psi tensile strength for demanding repair applications.

Low heat input — helps reduce overheating and distortion when working on sensitive components.
Excellent for dissimilar steels — useful for joining low-alloy, high-alloy, tool and carbon steels.

865 or 878?

Choose Eagle 865 when the job involves broken bolt removal, low heat input, build-up, tool steel, or dissimilar steel joining.

Choose Eagle 878 when the main requirement is a high-strength, highly ductile repair weld on difficult-to-weld steels.

In simple terms:
865 = stud pulling + low-heat difficult repair
878 = high-strength, high-ductility repair

1/16" / 1.60 mm — 20–40 A
5/64" / 2.00 mm — 40–60 A
3/32" / 2.50 mm — 60–80 A
1/8" / 3.25 mm — 90–120 A
5/32" / 4.00 mm — 125–160 A
3/16" / 5.00 mm — 160–180 A