Removing broken exhaust stud Options

[Rand]

Taking one of the nuts off, the stud broke.

I welded a nut to the end of the stud so I could get a socket on it, but she doesn't want to turn. Feels like it will break again. So I've been hitting the stud with PB Blaster. I could heat it with a torch. Hopefully it will come loose, but I may end up having to drill the thing out and tap the hole for a step stud. Grr, right before WCR (IMG:style_emoticons/default/headbang.gif)

Any suggestions?

[HAM Inc]

I've encountered every level of "frozen" when dealing with exhaust studs. I have also tried every trick for removing them. The only method that works consistently is heat and PB Blaster. Don't let the head cool to much or the stud will just freeze back up. Heat the boss, but not the stud itself (it weakens the steel) spray it with PB. When the head cools enough th stop boiling the PB then try to break the stud loose. If it won't budge then heat again. If it budges don't get greedy. Rotate the stud back and forth to the extent that it will move freely while spraying it PB. Increase the amount that you try to unscrew slightly all the while twisting back and forth. The rotating back and forth helps work the stud loose. If you try to unwind it all at once (if it's really frozen in there) it will break. Some studs will break and that is just all there is to it.

BTW Zach I tried the nut weld/impact idea. Seemed like a good idea, but it just broke the stud nearly every time. The key is heat and gentle application of torque while rocking back and forth. It's a high profanity operation anyway you slice it when laying under a car.