[nkaminar]

Yes. Part of the problem is that the weld does not get good penetration on the stud because it is cold and heat sunk by the block and my little wire welder does not put out enough heat. The other problem is that the stud does not get hot enough on the first try. The heat is really what enables the stud to be removed.

I did not find much rust in the threads. I think either the studs were too large for the threads in the hole, the threads were not cleaned out properly, that someone tightened the studs too tight, or all of the above. The studs should go in a little more than finger tight, assuring that they go in all the way, and anti seize should be used. There was evidence that someone had worked on the engine in the past.