Figured I’d post a new topic after reading and viewing MUFFLER.
I now own two VW Beetles, a ’69 and a ’74. Having replaced the exhaust on these VW’s a few times since the 1960’s, I have experienced a plethora of snapped exhaust studs.
I recently had this situation with my ’74 Beetle. I was able to grind the stud flat, center punch drill (angle drill fixture) and retap the stud to 8mmx1.25. Same method as the MUFFLER thread.
However, when I installed the new stud, I used a 8mmx1.25x35mm long snub nut that has a metric hex on one end. I slathered it up with anti-seize and installed it. Easy installation and removal and a hollow, hexed center in case I need to drill it out.
I buy a lot of hardware from McMaster-Carr (http://www.mcmaster.com) online. They are like Grainger on steroids. The part number for the studs I used is 91390A149. They were $11.56 for a box of 25.
I also use 8mmx1.25 copper locking nuts. Brass would be OK too. It’s way easier to get these off leaving the stud intact, than a steel nut that has cooked itself to the stud.
I have a “hot rodded” VW motor in an engine stand in my garage undergoing some upgrading. It’s exhaust studs in the aftermarket “042” heads have been replaced with these type “studs”.