Unless all the foreign metal from the old stud has been removed, you run the risk of breaking another tap. The thread chaser or tap should only be used to clean up the damaged cast iron threads from the chisels, punches, and picks used to remove the fragments of the old stud.
Please don't try to cut out old stud threads. You have done that once already and it didn't work. I call that method "cheating". You will probably get another failing grade. How many "Acks" are you willing to endure? Use heat, picks, and small chisels to remove the old stud fragments. Don't worry about buggering up a few threads. You have plenty to secure a lousy water jacket cover. And there is always epoxy thread repair material.
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Today's Featured Article - An Old-Time Tractor Demonstration - by Kim Pratt. Sam was born in rural Kansas in 1926. His dad was a hard-working farmer and the children worked hard everyday to help ends meet. In the rural area he grew up in, the highlight of the week was Saturday when many people took a break from their work to go to town. It was on one such Saturday in the early 1940's when Sam was 16 years old that he ended up in Dennison, Kansas to watch a demonstration of a new tractor being put on by a local dealer. It was an Allis-Chalmers tractor dealership,
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