Thats it cauter pin time!

Thanks for all the ideas and responses guys I'll let you know how it all pans out.

Another option is to get rid of the studs and nuts and go with Allen head cap screws with lock washers. There is no requirement to use studs. Ace Hardware has 6mm grade 8 capscews (black ones) I think they need to be about about 30mm (1 1/4") long for a standard exhaust manifold flange. Part of the problem with the nuts is the weld at the flange that will not allow the nut to seat properly. Test and you'll probably see that the nut will contact the weld bead and not lay flush against the flange when tightened. To remove the original studs simply double nut them and back them out with the nut closest to the cylinder. You'll want to stay away from the red loc-tite. It holds, requires lots of heat to soften and can damage threads if you ever need to remove the nuts or studs. Good luck, keep us posted on your fix.
Tom

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Age and Treachery Will Always Triumph
Over Youth and Skill

Thanks, I would try that but I have replaced those studs and I locked them in place with titanium high temp epoxy. I am not so sure they will be easy to remove, if all else fails I will get them out though. I'm going to try a few other ideas first. I do see what your talking about with the nuts not being flush like they should be. I love this place! Congrats on the Moderator Status 2Door!!

Thanks Terron,
Be careful trying to remove the studs. That titanium stuff might not let you get them out. I've used a grinder and shaved some of the weld bead off the flange, just enough to flatten the nut seating area. Use new lockwashers under the nuts, tighten them just enough to flatten them then double nut. Good luck my friend.
Tom

__________________
Age and Treachery Will Always Triumph
Over Youth and Skill