As a lurker I know this is a very largely discussed topic already, but I am at a loss and could use some creative ideas on how to pursue an issue I have. I have (and have had for a while) a snapped stud on my O2 housing that is causing me a lot of grief. I know these things are troublesome for just about everyone that has attempted to remove them for whatever reason. Well long story short, I have just recently purchased my 3rd set of studs with lock nuts from Beyond Redline, because leaving the snapped stud alone and trying to leave it with 4 always ends up leaving me with an exhaust leak after a month or so of driving. I really need to extract this last stud so that I can replace the gasket, and put all 5 new studs in that I have. Problem is that the snapped stud that is in there has no exposed threads that I can work with, and no amount of PB Blaster will free it so that I can get it out with vice grips. Trust me I've tried. If I had a drill bit that was small enough to drill the stud out, I am not confident I'd have the space to drill it out anyways, and I'd really rather not mess up the threads. The only thought I've been able to muster would be to carefully weld a nut to the tip of the stud and hope that putting a wrench to it breaks the stud loose rather than breaking the welds. I however do not have a welder, and would have to wait to borrow it from a friend.
I can't post the pictures that I have because my post count is too low. Just trying to get some insight before I get back to work on it since its flooding outside, and I'm kind of trapped right now.