Hi Andreas,
Many thanks & happy to share! Hopefully will help you get through my learning curve a bit faster along with gathering all the tools and materials!
A few other tips:
The impact wrench set up is at https://youtu.be/8GvdGMLWatQ?si=5XqIV0HritUdyNF6. Don’t use the impact wrench to tighten the nuts though, the torque that it can apply would probably crush the GRP hull, hence the 210nm by hand with a torque wrench. I used plenty of sikaflex to seal the stud in the hull thickness of the hole and under the washer. I also used a nickel grease to avoid the nut galling on either the stud or the washer.
When removing one of the old studs by hand, I found that the nut came off leaving the stud behind. It was easier to dig out the old sealant around the stud with a small screw driver, and then put 2 x M24 half nuts on, locked together ( I used 2x36mmAF combination ring spanners) to turn the stud out. I was surprised at how much friction the sealant gave in fighting against the stud coming out! Once out and cleaned up I could turn it back in by hand. I did need to clean the threads on the stud though first with an M24x3.0 die nut - which takes a 52mm box spanner.
An alternative method of removing the studs, particularly if the threads are bad at the top or under the nut is to use a roller cam type stud extractor. The only draw back is the clamping action does damage the threads - acceptable if they are being changed out.
If the nuts were too far gone to take an impact socket, my plan was to slit the nut with the dremel and use the stud extractor.
For one of the stud holes I had to use an M24x3.0 tap to help clear the threads.
I made the new studs (16 of) slightly longer at 105mm to take a lock nut in future to turn it out - avoiding the stud extractor. The originals were only 3 1/4” ~83mm. The studs were made from M24 threaded bar in 316 stainless steel, which came in 1 meter lengths and cut down with an angle grinder using a metal/stainless slitting disc. With 2m of bar I made 18 studs with 2 spares! The ends had a chamfer applied with a de-burring/chamfer tool which fitted my cordless drill, although there was some final de-burring with a needle file to take the last of the sharp edges off.
The only item I bought and didn’t use was a 36mm slogging spanner. Firstly, because it was too big for my original nuts and secondly, I couldn’t see how I could hit it with the lump hammer in the confines between the two hull ribs!!
Rgds
Simon