Yep.

Not the best situation to be in... was screwing in a new stainless manifold stud and SNAP. Not a happy chappy.

Has anyone had the same thing happen and able to get it out without taking the cylinder head out?

Or, should I take the cylinder head off anyway and see what other improvements I can make?

Thoughts?

Take the hesd off. If you bugger it up trying in situ, you'll be in a worse pickle.
Note- SS studs are not high tensile. Ditto the cheap plated studs that some Mini shops are selling now, they break real easy.

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

Don't use an easy out, I've heard more horror story's than successful ones. Being as also makes it a bit of a challenge. I would take it to a machine shop unless you have access to the right tools.

A nice trick that I've used is a center punch and hammer to try and spin the stud loose but that requires a bit of space

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77 mini sunshine: the slow build continues
http://www.ausmini.com/forums/viewtopic.php?t=70699

Depending on how much is sticking out you could try welding a nut on. It won't matter if you weld a mild steel nut to a stainless stud.

You'd need the patience of a saint to drill out a stainless stud - unless maybe you can source some left hand drill bits, which might wind it out.

Tim

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1951 Morris Commercial J Type Van
1955 BSA C11G
1961 Morris Mini Traveller
1969 Triumph TR6R
1977 Leyland Moke Californian

Weld a nut onto it and wind it out if you can other wise pull head off and drill it out

Looks like i'm taking the head off! I can polish the ports and check the condition of everything else this way also.

Not going to be able to weld anything to it unfortunately, nothing is sticking out, it's actually got about a 2mm recess...

Anything else i should take care of while the head is off? This will all be a learning experience for me as I've never done it before.

Cheers all

If you decide to try and go the drill out route, you select a very slow speed on your drill bit when drilling stainless. also ensure you use some cutting lubricant.
Be extremely cautious otherwise you could end up being a "double snappy unhappy chappy"

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"Investing my Super in a Cooper" &
"Re-living my Surfing Past in a Woody"