The Mashed Spigot: a Halloween Horror Story

[plurbo]

Rebuilding an '84 3.2. Here, we see that I was able to remove the final inch of a broken head stud from the case, but left a mess. Method: I successfully welded a washer+nut onto the stump without damaging the case, but then I did not make sure all 360º of the washer were fully clear of the lip of the cylinder sleeve AS I TWISTED OUT THE BOLT. I had to do a lot of grinding on the nut with the cutting wheel and I'm still left with this shameful divot.

In my defense this was the first of three nubs I had to remove and I improved as I went. See progression, attached. Tip: clip a washer in half and use both pieces as a seat on which to weld.

This is a DIY project vehicle and I am not going to have the whole register re-decked, but I do want a mated surface for the base gasket. Advice, insults, supercilious bewilderment etc. accepted below...

[Henry Schmidt]

I cleaned up a couple of your pictures to get a better idea of what you're dealing with.
My thoughts are, weld the damaged spigots and surface all six to maintain a uniform cylinder stack.

No need to beat you up over this faux pas, you're probably hard enough on yourself.