[dropkicknick]

3 of 4 exhaust studs came out relatively easily. Last one has been a pain. I've tried a torch, welding a bigger nut, love taps from a dead blow etc.

So I finally cut it down and drilled out the center, except it's a little off center. I've gone as wide as I can, I fear next bit size up will dig into the aluminum. Everytime I try to use a spiral bit to extract, it just makes it wider.

In the pics, it's left exhaust port, right stud

Any tips for moving forward?

 

[dropkicknick]

I actually left 1/4in stick out when I cut it down so I could grab it with som chanel locks. It just twisted the end right off.

I was thinking heli-coil too but isn't it to far off-center to completely drill it out?

 

[dropkicknick]

It will depend on how much wiggle room the exhaust manifold gives you. I think it will be worth a try before scrapping the head for sure. The last alternative would be to fill the hole with a TIG welder and re-drill and re-tap.

Scrapping the head will be absolute last resort. I've already had to buy a used throttle body and other various odds and ends. I just want to get her back together and ride before the sun disappears.

I'll sink a stud into JB weld before I'll toss the head (jk). I most likely am over thinking it, I've extracted plenty of fused bolts before, but it's a first on something I own. I had decent luck till now. Finally breaking in my $500 snap on extraction kit I've had for 7 years. Shame only the lefty drill bits actually did anything.

I've been working this stud for 3 weeks, every day I spray it with PB blaster or wd-40 till i finally decided to drill it out the other day. It's still sitting there hollowed out. I think today will be the day when I put on my big boy pants and deal with it.

Still have to find a heli-coil kit though. Any tips for brand and where to buy from? Never had to purchase a kit for home use till now

 

[dropkicknick]

Time Sert's are better than helicoils.

Had to Google that. I remember watching someone install one of those to repair spark plug threads. They seem pretty heavy duty. Only problem is it looks like it has a lip on it and the exhaust manifold wont fully seal with one end raised up. I'll search and see if I can find a flush type insert

Edit: literally next page had flush inserts lol thanks for advice

 

[dropkicknick]

You can also countersink them too a little if that's the only kind you have.

They seem to last better than Heli Coils and won't get loose in the hole.

My exhaust likes to shake things loose already. I'm always finding something to loc-tite. I'll grab one of those kits and do it right the first time.

 

[dropkicknick]

Got the little *******. $500 snap on extractor kit-0, $5 pair of pliers-1. It was creaking and moaning the whole way out.

 

[dropkicknick]

To top it off, the threads are damaged but its shallow and the hole isn't misshapen. Definitely needs an insert but thankfully I dont need a new head. Thx for the support guys, I got the energy and fire back to start putting it back together from full tear down. WOOOO!!!

 

[dropkicknick]

Same thing happened to me on a rebel 250. I drilled it out and was going to try the coil but ended up going side ways. I ended up welding a stud there permanently I ended up selling it 2 years later and the stud was still strong

ended up with helicoil. my neighbor just happen to right size kit.

when i drilled, i put in the new studs around it so i could have a angle reference.

just finished putting it back together. runs amazing now