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?

[Bleyseng]

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?

Boy now there is a "shelter in place" project waiting to get done. That oil cooler looks plugged and so much dirt on the heads. Drop the engine and tranny and take it apart to clean up everything so it runs cooler as its a air cooled engine.