Broken Heater flapper box stud, options to repair?

[Elombard]

I should not have tried to take those nuts off.

The studs are welded into the body with no access from the underside. I think they were welded at the factory before the rockers were installed.

Any body have a solution short of removing the rocker metal?

Thinking about grinding it smooth and using a sheet metal screw to attach. Not sure I can drill it, might have to wait until the engine is out again.

[john walker's workshop]

If just one broke, the other two will do the job. I'd leave it as is.

[Elombard]

Thanks John,

Yeah I am leaning that way. Does not seem like there is any way to replace those studs with out serious surgery.

Also seems like the flapper box is very secure with 2 attachment points

[mellon595]

I drilled and tapped mine, worked a treat

[Elombard]

Ahh, so there is enough "meat" there to tap and just use a bolt?

[dafischer]

I'm with John. It's been 5 yrs since I replaced the flappers, and I broke one stud. The other two do a fine job of holding it in place.

[wrxnofx]

I was very nervous about this when I did the R&R to my flappers. The nuts that came off had the nylon locks, which I think helped. Slathered a ton of anti seize upon reassembly.

[911 Rod]

I broke a few of them and had to weld on new studs.

[jimtweet]

Originally Posted by mellon595

I drilled and tapped mine, worked a treat

Two will hold just for, but I also drilled and tapped a few