True Confessions (broken exhaust bolt)

[Guest]

Wow,
How timely, I got a set of original exhausts coming and I thought about those bolts being frozen and breaking off the heads. It's for a '79 GS1000E
and it appears that the mufflers on it are original. I'll give some really good thought before I attempt it, if they don't break free easily I'll probably take it to a shop.
I have experienced broken bolts before, changing the lower unit on a Johnson outboard used in salt water. The electrolysis corrosion built up between the aluminum housing and the stainless steel bolts. After breaking off half the heads, I consulted a mechanic who told me just torch the aluminun, I did and they easily came out, luckily I had enough bolt sticking out to get a vice grip on it.

Steve

[Skateguy50]

Ah yes I got you, forgot about those many tests you ran to sort out the 0 compression thing.

Yea keep trying for sure, but if you meet someone that has a welder that sounds like the best option. I was lucky with mine, got all new ss bolts and installed them with some antiseize on the bolts for next time... My pipes are pretty rough so hope to find some "new" ones eventually on the cheap.

Keep cooking and pb blasting then.

[Allie]

Well I cooked away today with no luck. I got the bolt so that it was starting to turn red, that's about as good as I will get it with my torch I think, it's not 'cherry' red. I hit it with the snow, no luck. I did that twice. I also tried heating the head area again, all of this was with the torch turned way up. No luck. It looks as though I've exhausted the possibilities of the torch, is there any point in repeated heatings?

Okay I have another confession to make, I happen to own a little MAPP gas welding thingy that I bought years ago, and when I read the directions I was too scared to put it together and turn it on. I could just see me blowing me up with it... I kind of think that in any event I lack the experience to safely wield that kind of heat around my cylinder head... thoughts?

My thought is that I'm done with it for now, the pipe can be held on tight enough with the one bolt to run it, I could ride the thing to the garage and ask them if they could weld a nut on it and try to back it out. Unless there's any likelihood that further heating by me would help I think that would be best, while there's still a good bit of metal for them to weld onto.

[Griffin]

can i barrow your horse shoe for the weekend?

This isn't the first time I've done this. It's a pain, but I've never had a problem getting the hole(s) drilled and tapperd correctly.

[Skateguy50]

If you assemble and try that little welder unit get some scraps and practice on that for a while until you think you can get it on the bolt.

[blowerbike]

This isn't the first time I've done this. It's a pain, but I've never had a problem getting the hole(s) drilled and tapperd correctly.

its tough to charge someone a decent hourly wage on the time spent.
plus i always end up going off center or breaking a bit while attempting this.
i bow down to the broken exhaust bolt extractor known as Griffen...

note:
not being a smart a$$...just wish i had better skills/luck at doing this.

[Allie]

If you assemble and try that little welder unit get some scraps and practice on that for a while until you think you can get it on the bolt.

I'm still afraid to even turn the thing on! :P

[bonanzadave]

If you assemble and try that little welder unit get some scraps and practice on that for a while until you think you can get it on the bolt.

You might but thats basically brazing. The nut will spin right off. Gotta have a wire feed. You could probably find someone willing to come out and do it. Maybe beg some good samaritan off CL. NO WAIT... Youll get axe murdered by them. Try a Vo-Tec that offers a welding course. Some student could zap that nut on in 2 seconds.

[TeamDar]

I have done it in the past by taking a stock exhaust collar and bolting it on the head with the remaining bolt. You try to center the broken stud in the center of the other hole in the collar. I made a drill bushing with the inside diameter the same as a tap drill for the bolt size and the outside diameter to fit the collar. Then you have a drill guide to drill the tap drill hole. With the center of the bolt drilled out you can run a tap in and most times the remainder of the bolt threads just unwinds out with the tap.
In Allies case, she should bake one of those kick-ass pies and take the pie and the bike to a good mechanic and see where that gets her! Dar

[Allie]

I'm thinking pies may go a long way in getting a welder out here.

Okay I dug that thing out I bought and it's actually a propane/oxygen cutter/welder. It came with propane but they say if you want the oxygen to last longer to us Mapp gas because it burns hotter. So I guess you could use Mapp gas alone for hotter flame than propane? Well I have used Oxy/Acetylene a couple times, even though it makes me nervous I guess I know enough to be safe - I still think my best bet is a pie lured welder.

[Griffin]

I'm thinking pies may go a long way in getting a welder out here.

Okay I dug that thing out I bought and it's actually a propane/oxygen cutter/welder. It came with propane but they say if you want the oxygen to last longer to us Mapp gas because it burns hotter. So I guess you could use Mapp gas alone for hotter flame than propane?

Yes.

Well I have used Oxy/Acetylene a couple times, even though it makes me nervous I guess I know enough to be safe

The hard part is that the head is aluminum and has all those fins designed to dissipate heat. During my last ordeal, I used MAPP gas to heat up the area around the busted bolts, and the area around the bolt was cool enough to touch within ten seconds.

- I still think my best bet is a pie lured welder.

I love pie. Not much of a cake person, but to me, any time is a good time for pie. Too bad we don't live closer to each other. A fresh pie could lure out a hole drilling and tapping pro to fix your dilemma.

[Griffin]

its tough to charge someone a decent hourly wage on the time spent.
plus i always end up going off center or breaking a bit while attempting this.
i bow down to the broken exhaust bolt extractor known as Griffen...

note:
not being a smart a$$...just wish i had better skills/luck at doing this.

No offense taken.


If I was better at removing stuck exhaust bolts, I wouldn't be a pro at drilling them out and tapping the holes.