Ok. I'll look for one similar to the factory stud. Hopefully this doesn't turn into a dealer item. Wish me luck.

Shouldn't be a dealer only item. It's just a simple stud with a crown or collar nut. Just make sure you get the same thread as the old one. Heck. Pick up an extra or two for that "oh fudge" moment.(hopefully you won't have 1 of those)

Trying to find a specialty part at Lowes/Home Depot can sometimes be a pain. It seems people like to rummage through those parts pins and get stuff all mixed up and out of order. Don't hesitate to ask a salesperson for help if you can't find the right part.

The stud should be M6 take it in with you!

Or better yet, head to Autozone, Advance, O'Reilly, etc.

Hardware bin fasteners from big box home improvement stores are of iffy quality and odd origins,

As to why the nut and the original stud have decided to "go steady", I'd not be surprised that the nut has been cross threaded since the engine left the plant in Tonowanda.

Good old gauling the like metals bond after thousands of heat cycles

SUCCESS!!!!! Found a head stud luckily from a friend that works as a service tech at Jennings Anderson Ford.

I went ahead and "snugged" all the studs down working from the middle out and no exhaust leaks so far. It also helped that I had my dad there helping me with his longer slender arms leaning into the engine bay hand threading the nuts back on the head studs. I thought i was so far away from completing this project, but after the nuts were all snugged, I thought to myself, hey, all that's left is the O2 sensors and tightening the catback! An install that should have only taken 2-3 hours ended up taking over 5 of actual work and I'd say another 2-3 of running around looking for the head stud and "specialty" tools. Not to mention the bad weather we have had here in San Antonio.

Ok, on to the description of the results.
I stood back and told my dad, ok pop, I'm gonna start it. Hopped in and started it. To my surprise after reading all the horror stories on the cobalt forums of a full exhaust on a 2.2 sounding way to ricey, it sounds amazing!!! It has a very mellow and DEEP tone, something I have only really heard on V-6 cars with exhaust mods. The drone is there from 1,500-1,900 rpm and is not to noticeable at highway speeds. WOT pulls sound so good to me. The Trifecta tune previously installed with the help of CJ is really shining now. On the right street I am able to chirp the tires in 2nd gear, but that could be because I had a ton of tools and jacks in the rear of the car.

Anyway, on to the pics!!

https://www.chevyhhr.net/gallery/fil...ader_after.jpg

https://www.chevyhhr.net/gallery/fil.../4/_552015.jpg

https://www.chevyhhr.net/gallery/fil.../resonator.jpg

https://www.chevyhhr.net/gallery/fil.../4/catback.jpg

https://www.chevyhhr.net/gallery/fil.../axle_back.jpg

https://www.chevyhhr.net/gallery/fil.../rear_view.jpg

https://www.chevyhhr.net/gallery/fil...aight_thru.jpg
Excuse the dirt all over the car. As I said the weather has been raining and humid, but today it started to clear up a little.

Thanks to all who offered me sound advice and also merging my posts into this one thread. For anyone looking to buying this combo, I recommend you do. The fit and finish is top notch, just take the time to do things right. The results will pay off.

Edit: All the splatter of oil you see under the header and down-pipe is all WD-40. I had doused everything before trying to uninstall as recommended.
Here's a pic of my bus waiting for its first kill with the new exhaust.
https://www.chevyhhr.net/gallery/fil.../3/6/4/bus.jpg

:thumb:
Just remember to do a retorque or check on all those nuts and such after a couple hundred miles.

Why you ask ? Long time ago I loaned a friend a Chevelle I had salvaged and was trying to sell. I had put new headers on it and told him to check them after a week or so. He didn't and the left bank header actually came loose and fell off of the cylinder head !

Oh crap. Yeah I'll be checking the nuts by Friday or Saturday.

Edit: Here's a small video of how the car sounds. The video never does the exhaust on our HHR's justice. This is a cold start and revving from 3-4k. It sounds much deeper and better in person.

Excellent nrvous1, now release the Sounds.....
http://40.media.tumblr.com/tumblr_m1...a11lo1_500.jpg

Very nice install, oh Danny boy, the pipes are calling!!!