Need help with broken exhaust stud

[stownhooligan]

Yeah its pretty bad, sheared off inside the hole, and thoughts, advice,ideas? The two options im considering are buying one of those drill guide tools for the head or pulling the head off and taking it to a machinist, as far as pulling the head is there anything i need to be aware of or careful of, never done that before...Thanks guys.

 

[stownhooligan]

 

[stownhooligan]

 

[nikfleisch]

Happened to me last season hd charged me 400 to replace it

 

[wolfo68]

find someone that can drill it out, most shops that work on bikes will have the equipment and won't charge anywhere near an hd dealership

 

[CrazyTexan]

My brother almost bought a bike with that issue. I was just gonna drill into it a little ways and hammer in one of those square-ish extractor tools..this was the front cylinder front stud which also was a clean shot to get at with a drill. Good luck. And if its a 3/8x16 stud on one end and 24 thread on the other, I have 3 bags filled with stainless steel exhaust studs I can send u if u want.

 

[wolfo68]

the studs are like $3 at a dealership

 

[Oldgit]

The break is clean so you should get it drilled. I'm doing this myself, bought a set of removal tools. You may need to use a punch to get a bead on the surface of that stud.

Failing that, remove the head and take to a garage thats willing to remove it for you. No guarantees they can get it out, but its cheaper to try and fail than not try at all.

 

[konarider94]

the drill jig is the way to go, i got one on ebay for a decent price. they work pretty damn good. i wouldnt bother with an extractor, chances are you will break that off in the stud and it will be that much harder to get it out.

 

[Stevenc150]

I always start with spraying/soaking hole with PB Blaster, than using a Very sharp tipped punch or tap and try tapping CCW.

Then move on to drilling if need be. -- Drill a pilot hole, knock a screw extractor in tight but don't turn it yet, freeze the head as well as the wrench - after it's frozen awhile take it back out (use gloves) & quickly break it loose before it warms and siezes back.

 

[mnbuellrider]

Wish you luck, this happened to me. Wound up wire EDM cut out then had to put a helicoil insert in. The p.o. of my bike really did a number on my header bolt though. Dulled out several different style mills before we went to the wire route. Again gooed luck yours looks cleaner than mine was.

 

[squidbuellie]

There are twothings you can do.
Since it's the back stud it's a little harder to do with out a 90 deg drill or tilting the motor.but it is still easy to.
First pull your exhaust flang off to use as your drilling jig. Then take It to home depo and buy a copper spacer/ copper washer that will fit in the exhaust stud hole with a 3/16 hole it. Then buy a good ( not cheap) drill bit and easy out.
Then bolt the exhaust flang back on the bike and use it as a drilling jig as long as your not crazy twisting the drill around you will be able to get it out.
Oh and side note when your using the easy out give it two twists to get it set then use a gas torch to heat the stud (you can use candle wax with the heat too) then it should come out like butter. If it dose not come out because you drilled it at a angle then you'll have to do step two
Drill the threads out and time cert it.

 

[garyphantom222]

I am waiting for mine to go the first time I try to remove the headers but if they break I have a son in law who can get them out easily,I can do it if I had the right tools but since he has them I will let him do it.

 

[NwRider]

Exhaust flange and a pipe to make a jig? Thats ingenuity right there squidbuellie.

I recently had my front mount bolts snap and after buying an extractor and reverse drill bit found out the came out easily...

I always start with spraying/soaking hole with PB Blaster, than using a Very sharp tipped punch or tap and try tapping CCW.

^^^Very good suggestion... try that prior to spending any of that hard earned cash. From the photo it looks like you have a nice edge to get behind with a punch. Tappy tap tap it until a thread or two are in view and try to get a grip with pliers or vise grips and back it out.

Patience and a beer help too. Good luck.

 

[Iamarchangel]

I know it's too late but for others reading this, here's the tool for taking the nut off the stud.

The heavy black piece comes off and it's 3/8 socket underneath.

This tool will help avoid these threads.

 

[djohnk]

^^ Great idea, I just purchased one to have in my toolbox. Thanks.

 

[NwRider]

^^Thats a good price. Those are great for breaking loose nuts/bolts without bouncing on them.

 

[slag kustom]

take a nut the same size as the stud and place the nut over the stud grab the welder and fill the nut in. let it cool a bit then unscrew the stud with a socket.


the weld will shrink the stud when it cools and the heat will loosen it.

do not use an easy out they just break.

 

[Blastonia]

Kroil is your friend. Clean around the threads with a pick or wire brush. Squirt some kroil in the theads and let it soak reapplying periodicaly. Maybe hit it with some compressed air to help push the kroil deeper into the threads. Then round up a pnuematic engraver, an electric one may work but ive only used a pnuematic one. Place the tip at about the 3 oclock position on the stud, get a dimple started and push up then ccw. Its going to be vibrating so be sure you have a firm grip. You dont want the tip to get in the threads or youll ass them up. The frequencies from the vibration are going to help break it free and back it out. Heat will help too but be carefull laying a torch on aluminium, it will go fast. Id use a heat gun on it. That should get it plenty hot. Ive had good luck with this method.

 

[stownhooligan]

Thanks for the replies fella's. I bought one of those jigs from Georges garage out in Cali and the fucker was a couple thousandths off center. I was going to use it to get a dimple started and drill a pilot hole from there. Instead I pulled the head off and im going to bring it to someone with a lot more experience than me.