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Join Date: Jun 2010
Location: Poulsbo, Washington
Re: Exh manifold? you don't need those anyways, right?
I've welded to studs that deep in before, TIG is your friend here. I used a washer, high gas flow and a lot of stickout. Steel filler (doesn't really stick to the cast iron), and get a good solid weld between the stud and washer. Once that's in place, I usually use MIG to weld a nut on, and spin the whole thing out of the hole.
If you have access to an oxy-acetylene torch, that's the easiest way. make sure you're very well covered up and there is nothing burnable nearby, then have a hose handy for the stuff you forgot about. Using a cutting tip, heat the stud, not the head, just the stud to glowing, then give a blast of oxygen. Nearly all the steel will blow right out. You will need to run a tap into the hole to make sure the threads are good, but this method is by far the easiest for deeply recessed studs.
Do not use an easy-out.
Yanmar 135D finally running again!
73 Ford LGT120 being restored here
Lawn Boy Promo 8070 and M21, C80 Gardener
Too many parts mowers