Exhaust stud woes, What's the next step? Options

[saigon71]

Nothing is ever easy on these cars...

My heat exhangers got some oil in them from the bad oil cooler seals, so I decided to pull them for a good cleaning. One exhaust nut was really difficult to remove. Once I finally got it off, I saw that the threads were galled.

Ordered some new exhaust studs.

Went to work removing the old one after researching 914 world.

Heated stud boss with MAP torch & sprayed a bunch of PB blaster.

Welded a nut on the end...nut kept breaking loose without budging the stud, removing small portions off the top of the stud during the six attempts.

Then welded a bar to the remainder of the stud and used an adjustable wrench for leverage. Heat & PB Blaster, working it a little at a time, back & forth. It finally broke free. Reheat & apply more PB. On about the 5th cycle, the stud broke off below the level of the head.

Engine is in the car & I'd like to keep it that way. What are my best options for getting this thing out now...and installing a new stud?

I've had horrible luck with EZ-outs on other applications.

Thanks!

[IronHillRestorations]

You'll get closer to hitting the center of the stud with a transfer punch. If you are going to attempt drilling it by hand, I'd recommend using a left hand twist drill bit.

If you haven't done this before, you might consider taking the car to a pro, or pulling the head and having a (experienced) machinist remove the remains of the stud. You've broken off whatever was left of the stud, including everything you've welded to it. If you aren't very, very careful the next step for the home mechanic is breaking a drill bit or extractor off in the head. This is my free advice.