Exhaust Stud Removal

Does anybody know of a safe way to remove exhaust studs from a 440 head. I've had bad luck, the studs break off and when I use heat the head cracks easy. I need to get the studs out of a new engine I bought so I can use my haeders. Thanks for any help.

I'd love to hear a good way too.

The only way I know is take them to the machine shop and let them cut'em out, my local shop charges $25 a stud or $30 if you broke an easy out in it like I did the first time.

I've found that welding a nut onto the stud with a mig welder seems to blast the rust off the threads. Maybe it's the current through the stud or maybe it's the heat?

I also drench them with Kroil or Heat penetrating oil the day before.

If I break one I weld a washer on end to the stud if there's enough metal left. You can mig real close to the head as the molten steel does not stick very well to the cast iron.

leave them in,,, you wont have any water leaks...

IF you try an EZ-out ... use a QUALITY one of the square design....NOT the spiral one.

You can try rapping them with a hammer before you double nut them. It tends to "shock" the threads to help break them loose....

Screw (2) nuts onto the stud. You use the nut that is closest to the head to remove the stud. That nut contacts the outside nut and they lock themselves together.

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Does anybody know of a safe way to remove exhaust studs from a 440 head. I've had bad luck, the studs break off and when I use heat the head cracks easy. I need to get the studs out of a new engine I bought so I can use my haeders. Thanks for any help.

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The heads crack easy with heat ??? What are you using a CUTTING TORCH ???

Headers , I'd leave them in if possible unless you are a Masochist and like having to drain your cooling system to replace a blown header gasket or replace the starter