This has been drafted awhile ( never posted ) this thread seems a good of place as any to place to tack it on to.
I puchased my Offy 400 heads , stud set , hardened washers, & nuts in 2018 from Speedway Motors . Around 6 months ago I started to hang it all together , it turned out the studs were all about .120 “ short resulting not getting a full nut of thread. It was going to be messy complaining so I decided to recess the hardened steel washers into the heads 120”, with that out of ther way I used Permatex # 3 on the coarse threads to the block, using the 2 nut setup to seat in the block , a quick try of the head going on, no way, proceeded to check studs as per. ( Photo 1 & 2 at 12 and 3 o`clock . ) Three or four of the studs needed help with a suitable sized hammer to help them stand up straight , suitable anti seize on the stud shanks and the heads went on fairly easy. On to the next problem , some where between 40- 45 ft. Ib on the torque wrench I pulled 3 studs on one bank 2 on the other ( torque wrench checked out ok ) off came the heads , I decided to stress test all the studs using a suitable sleeve to 55 ft-lb found another 4 dodgy ones , having no other viable option I drilled out a spare cast iron head as a tapping quide for 1/2” UNC , prior to tapping I machined a drill guide 1/2” od for the tapping drill size. ( Photo 3 )
Sourcing some Grade 8 1/2 “ bolts I machined and threaded the upper part for 7/16 UNF ( photo 4 ) the small collar ,100 “ high was recessed into the head surface and a Dremel eased the gasket hole as needed.
Thinking over my problem, I feel I might of left the block in the molasses tank too long and the threads not being protected by the studs and being a small surface area were compromised by the acidity in the molasses, also is the possibility that the rust build up on the bottom of the studs did some damage on removal. The fact that I used a 7/16 HT head bolt with grooves cut along it as a chaser might not of helped. It was a GM bolt, maybe sabotage.
I made the mistake of following Offenhausers recommendation of silver paint on the composite gasket , removal within an hour, no problem , after 4 months real pain in the rear end. Next install dry ! Ah, the fun of it all.