Farrrk Snapped Exhaust Header Stud Bolt

Best way to drill a stud out is start with a centre punch and mark the stud dead centre , then start with a very small drill , working your way up in size . Remember though , you dont want to match the stud size for size with the drill as you only need to take the core of the bolt out . Also a worthy point to remember is that the bigger the drill , the slower the speed .you then may be able to fit a stud extractor inside those holes and unwind the stud out of the hole . I have had success every time this way and have taken some massive studs out of some very precarious places .

[Sid Squid]

I know I'm repeating myself, but to be fair, we have been here before.

Unless the nuts come off immediately and easily, put the spanner down and get a hacksaw/die grinder etc, the nuts and studs are small and always corroded 'cos of where they are.

NEVER TRY TO UNDO THEM IF THEY ARE STUCK. It WILL end in failure.

Cut them off instead.

[21QUEST]

Forget pic earlier...yes , the downpipe is a state hehe

Originally Posted by Sid Squid

I know I'm repeating myself, but to be fair, we have been here before.

Unless the nuts come off immediately and easily, put the spanner down and get a hacksaw/die grinder etc, the nuts and studs are small and always corroded 'cos of where they are.

NEVER TRY TO UNDO THEM IF THEY ARE STUCK. It WILL end in failure.

Cut them off instead.

SS, you are indeed right and hence why I was initially quite annoyed with myself....cos I frigging knew that. Not having had any problem ever, I got a bit complacent plus I'd just got back from work but wanted to do some work on the bike.

It went something like this "Ooh, not coming out....think I need better leverage....pretty sure if I go to the other side, that should do it ....."

Once I had done that, I immediately knew I had messed up. Other one got the shock treatment and game out easy....albeit stud and nut in one go.


Thanks again for the replies. Story so far is, got some plusgas and Locktite 'freeze & release' for a dual attack . Loads of 'freeze and release' and plusgas and the downpipe finally came out.

Put a slot on what was left of stud but no joy. No big deal as was just a speculative try anyways.
Got a piece of cloth wrapped round it and soaked area with plusgas. I'll keep applying for a little while and I'm confident a stud extractor will get it off when I next go in .

Pete, I'm still coming....it's not the one penned for the AE .




Ben

Ben,

I've got a MIG welder and can use it.

I'm in kent as you know, not sure how far you are from me.

If I can help let me know.

[21QUEST]

Originally Posted by mattc

Ben,

I've got a MIG welder and can use it.

I'm in kent as you know, not sure how far you are from me.

If I can help let me know.

Howdy Matt .

I'll keep that in mind. Hopefully we won't need it. I'm not far from you being in Surrey so distance won't be a problem


Ben

[21QUEST]

A wee update. We have a result....it snapped off as I attempted to undo it, earlier today haha.

A friend is going to come down next week and helicoil it if need be.


Ben