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!

[ctc911ctc]

I started replacing all of my studs with the engine in.

After reading this thread (and trying with no luck to remove one) I am going to use the existing studs and the new copper nuts I purchased. This is an engine out head off job.

QUESTION: Exhaust leaks

I took the exhaust apart because of leaks, here are two pictures of Cylinder 3 and Cylinder 4 exhaust ports

Cylinder 3


And Cylinder 4



Seems that 3 is running a bit lean and that 4 is running a bit rich. Also, do the colors on the copper gaskets (new, ran them perhaps 2-3 hours) indicate that they are leaking?