DJ rebuild... piston damage....

[spanishfly]

Welded a nut on to the stud stub, looked good but it broke off .... does this often take several attempts? Any pearls?
Not making much / any progress with the blow torch or freeze spray with double nut and chuck gripper. If just one would come out it would feel possible...

[Oldiebut goodie]

Blow torch on the ally and freeze on the stud immediately on removal of heat. I don't envy you trying to do it.

[Stesaw]

Try to tighten one gentley after heating it might help release it. I used a breaker bar on my remover and when putting pressure on the stud id tap it end with a hammer to shock it. I ended up rocking the bar back and forth gently on the stud to get them to start moving, although still didn't help me as 4 broke.. 

Takes a bit of grunt to shift them but once they make that horrid ping sound you can generally shift them. Just dont go ape on them and take your time. I was going to try welding nuts onto the end of my broken studs but after thinking about it I took it to a local engine shop as I thought they'd do a better job... I was wrong about that.

[spanishfly]

Thanks for the hope! I've been grinding down nuts and welding them on 5 times so far, everyone a better weld than the last but still not moved. Will persevere!
 

[spanishfly]

Pushing on whilst awaiting parts. I can't remember whether the longer of the straight original tank straps goes on the right (looking forwards)? Not obvious in Bentley, thinking longer on the right??
??

[spanishfly]

This must have been covered elsewhere but having now received what I hope are the missing parts of the puzzle, STD main bearings, hydraulic lifters and hopefully a Cam all that stands in the way (in terms of materials) are the corroded studs... if their successful removal is utimately unsuccessful and the case is too damaged to reuse would a 1.9 DF case with the same serial 025 101 101 B work instead? or are there other differences that make this difficult?