Broken exhaust Bolts HELL times 7.31 million

[MillerBuell]

Soooooooooo awhile back ago my muffler flange that goes over header collector was basically cracked all the way around. got that fixed few weeks later header pipe cracks all the way around leaving me with the front header tube as one piece and the rear header tube and collector has another piece. so take those pieces out. go to take muffler off... ALLLLLL 3 bolts, 1 in the front and 2 in the back muffler bracket bolts completely snapped off... rear two were a MAJOR pain in the ass, but get them out, threads still good and all! Golden right!? wrong... go to put new header back on, start tightening front exhaust flange nuts... SNAP! the rear stud on the front cylinder snaps in half... and no i didn't over tighten it, barely had any pressure on it. SOOO now tonight i drill into the stud and try and easy out it... doesn't budge. got a cotton ball soaked with some penetrant shit taped to the "stud" and gonna let sit over night. gonna try heat'n it up a little and easy out'n again tomorrow night hopefully. anybody got suggestions for an easier way? or proper way? or any way? also never really paid attention to it before we put new header on. but front cylinder around the port like on the head is alll black... rear cylinder is silver same color as the fins. i assume the front cyl. has been leaking for some time now. also 3/4ths the piece of stud that broke off looked to be like it's been "twisted/cracked" for awhile with a black/rusty color on inside of it and the other 1/4ths where it looked like it was barely hang'n on was silver and "clean" .... any help as to what went wrong or what i should do next would be greatly appreciated. adios

 

[tuneport67ss]

YOu are on the right track to getting it out. Let it soak and then apply a little heat. Try not to get the heat to to much around it or you could burna gasket out or warp something. It sounds like the header gasket blew out and weakened the stud. Repeated heating and cooling of the steel will weaken it. With all the parts cracking and breaking, it sounds like you are getting bad vibrations in the exhaust. Do you have aftermarket pipes on it? When you put it back together make sure all the brakes fit properly and everything is good and tight. Hope you get back on two wheels soon. Keep us updated on te progress.

 

[MillerBuell]

nope just buell "race" pipe. when u say brakes what do u mean by that!? gonna try her bright and early tomorrow hopefully she "pops" out. thanks for the help. tuneport67ss... sounds like a bitch'n ride my friend!

 

[tuneport67ss]

Sorry I ment brakets not brakes. My bad. Guess I should proof read. LOL[smirk]