exhaust manifold stud replacement

["Brandon Hull" <brandon@cardinalventures.com>]

While I'm on the topic of obscure tech tips:  At the urging of many old
hands, I replaced all the em studs on my 3B engine, prior to hanging on the
new RS2 manifold.  Despite the many warnings, the first one I tried snapped
off immediately, despite two weeks of penetrating oil soaking.

For the rest, I used mild heat (propane, on the stud only), plus more
penetrating oil and very paranoid application of torque, and they all eased
out with only moderate drama.

After three broken easy-outs, several hours with a diamond tipped dremel
tool, a 1/2"-8mm threaded insert and tech support and custom drilling jigs
courtesy of Igor Kessel, I'm back in business.

Take-aways?

1) Use heat:  If it's only propane, no way will you damage the head- it
stays cool to the touch 1 inch from the site, and I believe it might "wick"
the penetrating oil into the threads.

2) Forget the easy outs.  I'd try and drill the broken stud as close to the
threads as possible, maybe grinding with the dremel, and attempting to work
the threads out with a dental pick.  It won't work, but you'll have at least
done _something_ before resorting to the massive surgery of the threaded
insert.

Thanks to Igor and the List,

Brandon Hull
'91 CQ + everlasting 3B project