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!

[ThePaintedMan]

This is one of the most well-thought out and brightest ideas I've seen here for a long time. An example of what can be done with some ingenuity and plenty of forethought and patience. Congratulations on a great job!

Two things:

1) Can we make this a classic thread?
2) Hopefully no one else ever needs to go through the trouble that you did, but just in case, PLEASE hold onto that jig you made up! Someone else might be able to use it someday, or at least copy it for their own use.