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!

[Cap'n Krusty]

"New" exhaust nuts? Good luck finding those. I may have one or two used ones left; I keep finding them as we go through the stuff in the barn. They're Helicoiled on the inside, and should be fine for reuse. ALL the replacement nuts sold by almost everyone are of the locking variety, which were NEVER intended for use in this application.

The Cap'n

[Bartlett 914]

"New" exhaust nuts? Good luck finding those. I may have one or two used ones left; I keep finding them as we go through the stuff in the barn. They're Helicoiled on the inside, and should be fine for reuse. ALL the replacement nuts sold by almost everyone are of the locking variety, which were NEVER intended for use in this application.

The Cap'n

Would you mind showing a pic of the proper nuts? May these can be produced. What about SS nuts

[stugray]

Would you mind showing a pic of the proper nuts? May these can be produced. What about SS nuts

Last time I installed mine I used 8mm "Jis Nuts" from Ace Hardware.
They have a smaller OD so that you can use a smaller socket.
My aftermarket headers dont fit as nice as the stock, so I needed the extra room.

Once I torqued them to spec, I double nutted them.

Oh! ANd excellent job on drilling the stud out.
You clearly DO have the patience and forethought to do it right.
You should keep that drill guide kit handy and offer it to others as this happens to them.