Head Stud Lengths

[ironhorse]

I'm having more issues with the motor I'm refreshing (was supposedly rebuilt by a PO).

Previously, I removed the 3~4 head to have some repairs done. In the process, discovered that the PO failed to reassemble the motor with all the necessary parts (no lower air deflector plates, no thick washers under the head nuts, no O-rings, and no wave washers under the rocker assembly nuts)

Last night, finally reassembled the 3~4 side correctly, adjusted the valve clearances ...



... then moved to the 1~2 side. Found the same issues so far - missing deflector and wave washers for the rocker assembly.

I started to remove the head nuts, but I can't get the Allen bit to grab two of the upper nuts. The heads of the stud are almost flush, looks like they're less than a 1/4" below the surface of the nuts




I made some slots in one of the nuts and soaking with PB Blaster right now, will attempt to pound it CCW enough until I can get the Allen bit to grab.




Not sure how to tackle the second nut ... it's recessed a bit further into the head. It's also soaked with PB now.




I'm thinking all I can try is to drill two or three small holes around the perimeter of the nut and chiseling until it breaks apart ... Any suggestions from you guys?


I have no idea how the PO even got these nuts so far onto the threads. Are the upper and lower studs normally different lengths? Maybe the PO install the wrong studs?

[ironhorse]

I was able the get the easier nut off ...




... but the second one is proving to be a little more of a challenge




Will attempt a second drilling session, 180 degrees out from the first hole ...

[NICE 69 S]

If all else fails, you can cut the stud.
Bob B

[ironhorse]

Actually that had crossed my mind and just might be the ultimate method, Bob. Just when I thought I was starting to see light at the end of the tunnel, something else pops up.

I'm thinking there are at least two wrong length studs in this motor and will need to source some replacements anyway ... will update with what I find, but it's just been too darn hot to work in the shop these past couple of weeks - even late at night.

[ironhorse]

OK, Bob, took your advice. Dremmel tool to the rescue ...







... and stud remnant removal







I also had to remove a second upper stud that was too short (missing some threads at the tip)




Now, off to search for a couple of used studs and good two barrel nuts ... and my ring compressing tool.