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Discussion Starter · #1 ·
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?
 

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Discussion Starter · #6 ·
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?
 

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Discussion Starter · #9 ·
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
 

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Discussion Starter · #13 · (Edited)
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
 

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Discussion Starter · #19 ·
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!!!
 

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Discussion Starter · #30 ·
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
 
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