Broken exhaust stud... how to remove? Options

[x98boardwell]

The exhaust stud broke off. It has about an inch showing out of the cylinder (but does not have threads)..

How to remove? I know this has happened before and you will have the perfect solution so I am waiting patiently.. I know these are never easy.

Remember, there are no threads left (cannot use two nuts sandwiched together) so I would like to try and get some sort of broken screw removal tool to fix... and would like to find a local alternative so I can fix over the weekend if possible.

Thanks for the help in advance,
Bryan

[Rand]

I had one that was frozen super tight. I tried welding a nut to the end, but it was tight enough to just break the nut off. I ended up welding a piece of flat bar along side it so I could get a good strong weld. Then a big crescent wrench on the flatbar.

Here's the process that made it work though:
Heated the stud and area with a map gas torch.
Sprayed it with PB Blaster.
Tried turning it... But not so hard that it might break.
Repeat repeat repeat... It took several cycles of heat and penetrant before it would budge.
Once it budged, I didn't just try to screw it all the way out. Turned until it started binding, then back & forth. A little more each time.

Then the problem was it took some of the threads out... The aluminum galled and stuck in the threads of the stud, rendering the hole useless. I had to tap it the next size larger and use a step stud.

Old thread here:
http://www.914world.com/bbs2/index.php?showtopic=85775

[x98boardwell]

Thanks again guys,

I have no rust as it has been a desert car it's entire life. I have already sprayed with lubricant and was hoping to just grab the end with a broken removal tool and go from there.. not able to weld unless I have someone come over to do it for me.

Thoughts?

Bryan