front downpipe studs rotten!!

[dusty1969]

having got over my reg/rec problem the other week my latest "snag" of my 1997 firestorm, the front exhaust gasket blew,ordered new gaskets started stripping exhaust and one of the studs rotten, i have ordered new stainless studs and nuts online.
anyone had fun removing studs on thier storm before? the nearside one has snapped internally so cant get anything around it,could try drilling?with a steady hand? cant get in with a dremmil cutter to make screwdriver incision? oh the fun of" rusty nuts"

[Wicky]

Have a search as the problem has cropped up quite a few times before with differing solutions depending on the severity of the broken stud.

[VTRDark]

Not nice. From experience I will tell you that trying to drill it out with the cylinder head still mounted to the bike will make things worse. If you have some broken stud protruding then your best bet is heat, extreme heat (welding heat) get a nut welded on the end and have it undone.

(:-})

[darkember]

Yes pain in the butt. I ended up having to remove the head and had it professionally drilled out and new time-serts fitted. Check the following thread out as you will see I had a really good bit still left but is still snapped.

http://www.vtr1000.org/phpBB3/viewtopic.php?f=9&t=31500

Ended up having to do the following

http://www.vtr1000.org/phpBB3/viewtopic ... 0&start=30

[dusty1969]

good tip darkember,
i have had a nightmare drilling the said stud it has been bodged up by previos owner/owners ,basically the stud has originally snapped 5mm deep below flange!! that 5mm was filled with bodge(possibly a sh1t weld snot) which has come away also the head flange has been over(outsized) within that recess so the first 5mm will not re tap as there is nothing there!!!!!!!
my next step after admitting defeat is to take it to my local MOT/Bike repair shop, and put my trust in the expert?? who i trust in his experience(40 years bike mechanic)
what options do yo think he will throw at me?? ski p the bike?
remove head and re-drill/tap ???
helicoil????
drive myself to drink????

[dusty1969]

i have given in to defeat as i have no heat,welder,etc my mate the mechanic wouldnt take the job on but a scooter garage around the corner is going to drill and helicoil in situ on thursday(good luck)
if that fails it will be a head off,workbench,drill,tap and new gasket jobby??

[tony.mon]

You can drill the section in the head out to M8 or even M10, then get a stud made with a fat M10 base and an M7 stud for the flange to bolt to.
Although it's just as easy to use M8 stud/M10 base section and drill out the flange- lots stronger and less likely to fail, a few grams heavier though.
Any machine shop can make the custom studs.

Or just drill and tap M8, wind in a high tensile bolt and saw the head off....

[dusty1969]

hey up tonymon
good advice,
the guy from the scooter shop,snapped the bit from the helicoil kit,so had to fill out the void with weld and then add a nut at the pretruding snot of weld.cooldown and do the old"lefty loosey"the old skool way,i was impressed and gave a tip on top of the charge(very reasonable)so he replaced with the stainless steel studs which i ordered online,well impressed and im back on the road,