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 - Measuring with Calipers - by Staff. The legs of inside calipers are curved outward at the extremities to facilitate measuring small holes, while outside caliper legs have a large curve inward to increase their capacity for large work. Firm-joint calipers are adjusted approximately by the hands and then set to the feel of the work by tapping them on a metal surface. It is a common practice when opening calipers by this means to tap the top of the joint. It is better, if possible, to tap the inside of the legs, as repeated blo
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