Despair? Its a stud nightmare

[pouch]

Reached a pretty low ebb on the engine fitting today.

The Vege recon is in now, tinware powdercoated and fab, managed to get a new Heat exchanger (NOS) and the manifolds are ready for the twin 40 Delllorto I will be running to give me a bit more grunt as I will be towing a bit.

Only snag is the Dell manifolds are deep and use a captive bolt on the outside instead of the stud. removed 3 of the studs quite easily (I don't think they are new, but in good nick) The last one was turning, then jammed, manged to get it moving again, but wont budge past a certain point. 4 hours of wriggling back and forth through 8 alloy nuts and the stud is starting to look a bit ropy. lots of heat, loads of lube. no joy.

Eventually, it shears....

So do I take the newly fitted engine out or find someone who can drill in situ?
I have tried drilling out before and it is not something I want to do again...

Seems like this refurb will never end...
Next stop pub..

[Mr Bean]

Reached a pretty low ebb on the engine fitting today.
Only snag is the Dell manifolds are deep and use a captive bolt on the outside instead of the stud. removed 3 of the studs quite easily (I don't think they are new, but in good nick) The last one was turning, then jammed, manged to get it moving again, but wont budge past a certain point. 4 hours of wriggling back and forth through 8 alloy nuts and the stud is starting to look a bit ropy. lots of heat, loads of lube. no joy.
Eventually, it shears....
So do I take the newly fitted engine out or find someone who can drill in situ?
I have tried drilling out before and it is not something I want to do again...
Seems like this refurb will never end...
Next stop pub..

I don't want to talk you into something you wouldn't be comfortable with but if the stud is just a bit proud I have arc welded a nut on the top in the past. The nut needn't be the correct thread just as long as it fits after a style. The heat can do wonders and often breaks the jam. If it fails nothing lost providing you don't damage anything in the welding.
Life can be full of poo sometimes can't it! I can't sympathise enough.
Regards
Ken

[pouch]

I think I need to find someone near Bristol who can drill out for me.
We tried the sip welder, but could not get the weld to take against the stud