I know what you mean with the price but for the guy in his garage what else is there that will reliably get a broken stud sorted out, excluding welding which I suspect many of us don't do.

A few people have warned against using extractors only for some to come back and say they made the situation worse snapping one off to compound the problem.

 

OP, Flan, interesting journey.... I'd vote the first step is to remove that broken stud !

Best advise from me is to soak the broken stud with Liquid Wrench, PB Blaster (specific thread/ corrosion looseners) et al every hour for days

Name brand extractors (instead of a Harbor Freight brand) may be a tool asset.

A propane torch may also be a tool asset, once you begin extraction.

Helicoil, retapping, modifying the flange decision, new cylinder head....the second step.

Again, good luck, I look forward to reading of your success.

 

what i plan on doing is using the Jig to drill the hole in the correct spot. I'll insert the exhaust stud and make sure that its fit correctly, then i'll fill in the surround areas with the tig torch. the ONLY danger in this is i'll have to use very little amperage while trying to get a puddle going with the torch, i'll be sure to be conservative with the filler rod and be extremely care not to get too close to the stud. Even if steel and aluminum dont weld together, it cant still be a damn mess. its going to be difficult but I can make it work. Good thing I know my way around a tig torch and the problems with welding cast aluminum.

 

thanks man, im really weighing my options, i deffinitly want to make sure i get it right though. its not the end of the world, just a head ache.