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Thread: Drilling out JB Weld from exhaust bolt thread?

  1. #31
    Join Date
    May 2009
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    Norman, Oklahoma
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    I agree on Timeserts. After using them I will not ever do helicoils again.
    MY BIKES..1977 GS 750 B, 1978 GS 1000 C(X2)
    1978 GS 1000 E, 1979 GS 1000 S, 1973 Yamaha TX 750, 1977 Kawasaki KZ 650B1, 1975 Honda GL1000 Goldwing, 1983 CB 650SC Nighthawk, 1972 Honda CB 350K4, 74 Honda CB550

    NEVER SNEAK UP ON A SLEEPING DOG..NOT EVEN YOUR OWN.


    I would rather trust my bike to a "QUACK" that KNOWS how to fix it rather than a book worm that THINKS HE KNOWS how to fix it.

  2. #32
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    Oct 2016
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    Indiana
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    As requested, pictures of the dilemma. First I will recount what I think I did wrong. I believe that in drilling out the old thread and what remained of the old bolt I wasn't perfectly straight and more than likely attempted to thread mostly aluminum and some remaining steel. I meant to say I used a 17/64 bit. So now I am faced with a weird spot. Do i try to continue to tap what I have, I am about 3/4 the way tapped. Or should I drill out larger to 3/8 and attempt to tap that. Hmmmm.

    Here is before I started tapping, you can see the old threads, maybe this should have been my indicator to not proceed yet.


    Here is where I sit now, the tap is broken flush after I attempted to use pliers to back it out.


    Well a learning lesson for sure, unfortunate it had to be so deep. Won't let this keep me from my third week of may deadline!
    1980 GS850G

  3. #33
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    At this point I think i would sacrifice a pair of needle nose vice grips and grind them till I could fit them down the flutes. Clamp onto that tap and use an adjustable Crescent wrench on the flat of the vice grips to turn the tap..again blow the chips out with the compressor and squirt lots of oil into the hole. Keep alternating with the air and oil to keep the chip build up to a minimum.
    MY BIKES..1977 GS 750 B, 1978 GS 1000 C(X2)
    1978 GS 1000 E, 1979 GS 1000 S, 1973 Yamaha TX 750, 1977 Kawasaki KZ 650B1, 1975 Honda GL1000 Goldwing, 1983 CB 650SC Nighthawk, 1972 Honda CB 350K4, 74 Honda CB550

    NEVER SNEAK UP ON A SLEEPING DOG..NOT EVEN YOUR OWN.


    I would rather trust my bike to a "QUACK" that KNOWS how to fix it rather than a book worm that THINKS HE KNOWS how to fix it.

  4. #34
    Join Date
    May 2008
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    Brisbane, Queensland, Australia
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    1,044

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    Quote Originally Posted by chuck hahn View Post
    At this point I think i would sacrifice a pair of needle nose vice grips and grind them till I could fit them down the flutes. Clamp onto that tap and use an adjustable Crescent wrench on the flat of the vice grips to turn the tap..again blow the chips out with the compressor and squirt lots of oil into the hole. Keep alternating with the air and oil to keep the chip build up to a minimum.
    Even needle nosed pliers would work ok - as long as you "tap" them into the flutes they should hold enough to back out the broken tap (fingers crossed).

    After that, if you have enough thread, Loctite a stud in there to mount your exhaust and call it done (actually, use studs on ALL the holes).
    Current:
    Z1300A5 Locomotive (swapped my Intruder for it), GS450 Cafe Project (might never finish it....), XT500 Commuter (I know - it's a Yamaha )

    Past:
    VL1500 Intruder (swapped for Z1300), ZX9R Streetfighter (lets face it - too fast....), 1984 GSX750EF, 1984 GSX1100EF (AKA GS1150)
    And a bunch of other crap Yamahas....

  5. #35
    Join Date
    Jun 2015
    Location
    Shelby, Ohio
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    Quote Originally Posted by Kodak View Post
    As requested, pictures of the dilemma. First I will recount what I think I did wrong. I believe that in drilling out the old thread and what remained of the old bolt I wasn't perfectly straight and more than likely attempted to thread mostly aluminum and some remaining steel. I meant to say I used a 17/64 bit. So now I am faced with a weird spot. Do i try to continue to tap what I have, I am about 3/4 the way tapped. Or should I drill out larger to 3/8 and attempt to tap that. Hmmmm.

    Here is before I started tapping, you can see the old threads, maybe this should have been my indicator to not proceed yet.


    Here is where I sit now, the tap is broken flush after I attempted to use pliers to back it out.


    Well a learning lesson for sure, unfortunate it had to be so deep. Won't let this keep me from my third week of may deadline!
    Definitely a learning experience.
    If you hit the bottom of the hole that tap will be pretty tight. At this point the tap extractor that gsrick mentioned will be your best bet.
    Apply some heat from a torch to the material around it, not too much and from inside the exhaust port.
    Get the extractor as deep in as you can and carefully try to work it out then in then out a little at a time till it's loose.
    Be careful because the extractor can break too. Vise grips at the hole on the extractor and a tap wrench at the top will give extra grip and stability.
    Get some good cutting fluid in there as well.
    As Chuck said, make sure you can get as many shavings out as you can first.
    Alan


    Weaned on a '74 450 Honda
    Graduated to an '82 GS850GL
    Now riding an '83 GS1100GL
    Added an '82 GS1100GL

  6. #36
    Join Date
    Aug 2012
    Location
    British Columbia, Canada
    Posts
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    I want somebody to try the alum trick suggested elsewhere on GSR... Granted, building a waterproof "dam" there is going to be tricky- a plastic straw or vinyl tubing might do it with silicone... Even if it only dissolves the thinnest ends of the tap threads , it is going to help. Maybe a paste of alum and water packed in .....

    http://forums.sohc4.net/index.php?topic=73735.0

    https://www.youtube.com/watch?v=fqZYgReuywM

  7. #37
    Join Date
    Jun 2015
    Location
    Shelby, Ohio
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    Quote Originally Posted by Gorminrider View Post
    I want somebody to try the alum trick suggested elsewhere on GSR... Granted, building a waterproof "dam" there is going to be tricky- a plastic straw or vinyl tubing might do it with silicone... Even if it only dissolves the thinnest ends of the tap threads , it is going to help. Maybe a paste of alum and water packed in .....

    http://forums.sohc4.net/index.php?topic=73735.0

    https://www.youtube.com/watch?v=fqZYgReuywM

    That's interesting. I saw that post but just blew it off.
    I wonder if it would just take longer on a hardened tap. His condition would be perfect to try that and let us all see if it worked.

    +1 on this idea.
    Alan


    Weaned on a '74 450 Honda
    Graduated to an '82 GS850GL
    Now riding an '83 GS1100GL
    Added an '82 GS1100GL

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