Thanks all for your help - this is how I fixed the broken stud issue.
I had about a 3/8" long remaining stud left that was broken at the firewall so I didnt think I would have enough clearance to put the Tube nut sleeve idea in place. The tube nut would have be larger than the bolt and would have been difficult to work with the existing holes in the firewall.
So per the video idea earlier
Quote:
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As for the ones that are part of the metal frame, there is a guy on YouTube that goes over replacing the heater core for his 1980 (or 1981, not sure) and he runs into the same issue and describes what he did.
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I air ground the stud flush and drilled out on center to tap a 1/4 - 20 thread in the aluminum through the ground off bolt. I threaded a stainless steel nut onto a 2" stainless steel 1/4 -20 screw and ran the nut to the screw head. I followed the nut up with a stainless steel washer. The Idea here is to use the nut as a jamb nut threaded against the tapped hole in the aluminum.
I threaded the screw in from the inside of the case out after putting locktite where the screw and nut threads would end up. I was careful not to put the locktite further out as I didnt want it where the case mounting nut will thread.
After threading the screw in up to the washer - I held the screw and jammed the nut by tighting toward the threaded hole to jamb the screw tight so it will not turn when threading the mounting nut on.
Thanks all for your ideas and help.