what have you done to your "bike" today

[Duffy1964]

Took the FJ for its MOT and passed
Then fitted Fazer mirrors ready for Devon trip


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[rollingthunderx2]

Second weekend trying to remove a snapped exhaust stud.
Welding didnt work
Dremelling a slit didnt work
Mapp gas dodnt work
Drill wont look at it so I reckon its stainless.

Having a break now trying to get a new fitted rear tyre to sit up on the rim..not being obedient..despite a ratchet strap around it.
Better get the beadbreaker out and start again...

At least its sunny.

[rollingthunderx2]

Second weekend trying to remove a snapped exhaust stud.
Welding didnt work
Dremelling a slit didnt work
Mapp gas didnt work
Drill wont look at it so I reckon its stainless.

Having a break now trying to get a new fitted rear tyre to sit up on the rim..not being obedient..despite a ratchet strap around it.
Better get the beadbreaker out and start again...

At least its sunny.

[tony.mon]

Pull the head off, it's much simpler then.

[rollingthunderx2]

Still leaves the problem of actually getting it out..
I have it up on the bench with the front end off as Ive been doing the forks.
Ive dremelled a slot and used a mapp torch and an impact gun with a good fitting bit.
The good drill wont look at it. I think theres a broken drill or something in there as the bit is clicking.
The header flange was welded on as well as being completely rusted.

[MacV2]

Still leaves the problem of actually getting it out..
I have it up on the bench with the front end off as Ive been doing the forks.
Ive dremelled a slot and used a mapp torch and an impact gun with a good fitting bit.
The good drill wont look at it. I think theres a broken drill or something in there as the bit is clicking.
The header flange was welded on as well as being completely rusted.

Theres a trick you can try... Cut a bit of the head itself off...

stud1.jpg (45.02 KiB) Viewed 1984 times

You'll have to do the other side to even it up...

Drastic but other than head off & take to a machinist you've tried everything else...

[yellabell]

Second weekend trying to remove a snapped exhaust stud.
Welding didnt work
Dremelling a slit didnt work
Mapp gas didnt work
Drill wont look at it so I reckon its stainless.

Send me a pm with your address if you want. I wont be able to reply so include a mobile number so you can text too if needed. I'll send you a few carbide drills which, if you use them as they get progressively bigger, should see the stud come out. Trick is to ensure the 1st drill goes in square and in the centre of the stud. If you can grind it off flush and get a nice new rust free surface you'll be able to get the centre of the stud easy. Centre punch it first before drilling. I'll send you a centre drill, spotdrill, and a range of drills up to the core size of the stud. Sometimes the stud will 'peel' out or sort of unravel as you get near the core size and you can pull it with pliers.

[rollingthunderx2]

Hi, thanks guys.
The stud is snapped off inside quite a bit in, ive already cut the casting back but dont really want to ho further back..Ive ground about 8mm off and its flat across the casting and stud.
Thats when I dremeled, welded thick washers and nuts on.mone of my drill collection will look at it.
The stud seems to be stainless, I centrepunched it square and the drill made a wee crayer but started catching on something and clicking.carbide drills would be worth a try.Thanks so much.

[tony.mon]

Stainless can still be drilled, the cutting angles you grind the drill bit to are a little different but not much. Removing the head enables you to mount it on a drill press table, guaranteeing that the hole is drilled vertically into the stud. It's also easy to set the hole depth so as not to drill into the water jacket.

The alternative is to take it to a machine shop and have it spark eroded out.

Or buy another head.

[yellabell]

Ok Don, I got your PM. If I'm right the studs are M7 into the block and take an M6 flange nut... someone correct me if not. That means the core size for M7 is 6.1mm diameter.

I'm sending you 2x centre drills, one with a 1mm pilot & the other with a 2mm pilot. That should centralise the drills.

Then there's 1x each of 1.5, 2.4, 3.5, 4.2, 5.0 & 5.8mm diameter drills. All solid carbide. Work your way up thru the sizes. FFS don't drill too deep! Safest bet like Tony says is to take the head off but up to you. Keep them square and central they should do the job.

I've put a 6.35mm dia drill in too for any M8 stuff that breaks in the future! Haha!

Keep hold of the drills if you manage to keep them intact. If it works doing it this method then other forum members might make use of them. Good luck fella.

[sirch345]

Ok Don, I got your PM. If I'm right the studs are M7 into the block and take an M6 flange nut... someone correct me if not. That means the core size for M7 is 6.1mm diameter.

I'm sending you 2x centre drills, one with a 1mm pilot & the other with a 2mm pilot. That should centralise the drills.

Then there's 1x each of 1.5, 2.4, 3.5, 4.2, 5.0 & 5.8mm diameter drills. All solid carbide. Work your way up thru the sizes. FFS don't drill too deep! Safest bet like Tony says is to take the head off but up to you. Keep them square and central they should do the job.

I've put a 6.35mm dia drill in too for any M8 stuff that breaks in the future! Haha!

Keep hold of the drills if you manage to keep them intact. If it works doing it this method then other forum members might make use of them. Good luck fella.

The stud that goes into the head is 8mm not 7mm, take a look here:
http://www.vtr1000.org/phpBB3/viewtopic ... eec479e1e8
The flange nut is 7mm.

Chris.

[MacV2]

Yep the bit in the head is 8mm, the external bit is 7mm as standard factory fit.

Aftermarket ones are often 8mm all the way...

The stainless ones I fitted were...

[yellabell]

Ahh right. Before I send out the drills then I'll put a 6.8 drill in too as that's the core size for M8.

[AMCQ46]

Got a new project.





Rd400 drag racer, not been run in a long time but engine had crank seals replaced 3yrs ago.

No cost as long as I race it


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[alanfjones1411]

You will have lots of fun with that Al.