Exhaust stud install after installing TimeCert, WTF?!! Options

[rjames]

Trying to keep calm after spending the evening freezing my ass off in the garage and hoping I didn't F things up worse than they were before I started.

I stripped an exhaust stud a while back and jk.76-914 was super kind enough to lend me his TimeCert kit, which worked like a champ. (I'll be sending it back to you very soon, btw). I got the new TimeCert installed, and then went to install the 9 x 8 step stud that I ordered from Jake's site. I was able to get the new exaust stud installed just a little over 1/2 way before it wouldn't turn anymore and after exerting a bit more force, it instead began to turn the insert as well. An attempt at removing the stud just unthreaded the instert completely. Luckily I had another instert to install as I couldn't get the old one off of the stud. BTW, I had to destroy the stud to get it out by using vice grips to unscrew it- it was in there that tight. I REALLY hope I didn't strip the new threads I made for the instert as I probably turned the insert about 1/4-1/2 a turn before I realized it was turning along with the stud. (IMG:style_emoticons/default/headbang.gif)

I ordered an extra 9 x 8 stud, and upon further examination it looks like the 9mm end isn't perfectly 9mm. I don't have a micrometer, but just by eyeballing it I can tell that it widens after a few threads and stays wider before tapering off again near the end of the threads. It's subtle, but it's enough to keep it from screwing in to my newly installed TimeCert.

Has anyone else run into this problem? Am I doing something wrong? Are all exhaust studs not created equal? Pics below. (IMG:style_emoticons/default/sad.gif) In the second photo, you can kind of see the curve of the 9mm side when comparing it to the straight line I drew. The 8mm side does not seem to suffer from this problem.

Since I bought the step studs from Jake, and I'm sure he's installed a few of these, maybe he'll chime in and explain what I'm doing wrong here.