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Why not try some JB Weld made for high heat applications. Says it's good for exhaust manifolds. Never tried the stuff but it might be worth adding to the new stud after it is installed in what's left of the threads. JB Weld - High Heat
I repaired a straight six Ford manifold on my 62 E100 with JB and it was still going strong six years later. Tough stuff and you can file it to shape, too.
A positive attitude may not solve all your problems, but it will annoy enough people to make it worth the effort. Herm Albright (1876 - 1944)
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