Are they weak from corrosion or were they overheated or overstretched?
If they are failing due to overheating, then the case has to be
carefully measured to make sure it is still straight.

My tick is to weld nuts on the piece remaining using a MIG welder. The
heat from welding also helps to loosen the stud.

Dennis

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf
Of Dyer Lytle
Sent: Monday, November 08, 2004 12:47 AM
To: vanagon@GERRY.VANAGON.COM
Subject: head stud frustration

Hi all,

I have been very slowly rebuilding the 1.9 water boxer out of my '84.
The failure that triggered the rebuild was a broken head stud.  I had
hoped the other studs would be OK but, alas, it is not to be.  While
torqueing down the 1-2 cylinder head another head stud let go.  I
decided
I should replace all the head studs since they can't be trusted.
Removing
the old head studs is proving to be a mess because they are all in a
weakened
condition and I have broken a few more trying to remove them.  I have
read the archives and have soaked them in penetrating oil, struck them
sharply on the end with a hammer, and am using an impact wrench to
remove them.  Unfortunately, the  shanks are weak and break.  One broke
near the base and will be hard to remove.  Has anyone had any luck
drilling the bottom ends of these things out?  Any recommendations?

Thanks,

 -Dyer Lytle in Tucson