Plan "A" didn't quite work
I saw last night that I had only about 3/16" of threads, but I had another 1/4" of unthreaded stud above that. I cut some new threads on that part and cleaned up the broken threads on the tip of the broken stud, but I just couldn't get enough threads on the second nut to crank them together and turn the stud out. So much for plan "A".
I appreciate your idea about heat, but I don't have a welding torch. I also want to try everything I can before I have to remove the manifold. I've never had good luck pulling steel manifold bolts out of an aluminum block on engines this old, so I'm leery about doing that cavalierly.
Plan "B" will be to cut a slot in the broken end of the stud, clean up the treads again, put a nut on it to keep the sides of the stud from spreading out, then turn it out with a screwdriver and a wrench for leverage. We'll see how that works tonight.
Plan "C" will be to remove the manifold, put it on a drill-press, and drill the stud out. (Yeah, I have a drill-press.) Then I'll re-tap the hole and proceed. Let's hope it doesn't come to this.
If I didn't need to weld something only about once every five years, it would sure be nice to have welding equipment. Maybe someday....
Scott
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