Broken Exhaust Bolt Exraction Idea

[chuck hahn]

I noticed that the NEW 78 project bike had a broken exhaust bolt last night. The previous owner didnt mention this and i didnt see it when i was looking at the bike. It was broke off about an 1/8 inch below the surface .. Here is how i handled it.. I first carefully drilled all the way through the broken exhaust stud taking care not to let the drill bit hit the bottom of the hole. Then i took a 1/4-20 LEFT HAND tap and tapped the center of the stud. Next put a nut on a 1/4-20 left hand bolt and threaded the bolt into the broke stud and jammed the nut against the face of the stud.. Put on a socket and just backed the whole thing out.. From start to finish took me an hour and a half and cost me 8 bucks in a tap, nut and bolt.

 

[Guest]

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I wanna see the replies on this one as I have a couple similar tasks I need to tackle myself.

 

[chuck hahn]

you see the physics behind it right? Since the exhaust stud is a righty tighty lefty loosey.. once the left hand blot tightens up it is applying loosening direction to the broken stud therefore simply unscrewing it just like it was never snapped.. it worked like a charm and the threads in the hole werent damaged on ioda. And just in case anyone wants to chime in.. I DID IT RIGHT IN THE FRAME WITH THE ENGINE STILL BOLTED IN...

 

[Zimquidl]

Now that's the way to do it!

At least you stayed away from the "EZ" out route. Those things are evil.

 

[chuck hahn]

I had the same thing happen on the first 78 750 except i snapped that one off. In that case i got lucky and it was sticking out about 3/16 of an inch. In that battle i just fired up th buzz box welder and welded thru the hole in the nut to the stug and hit it with the PB Blaster.. it came out effortlessly.. I did consider the ez out for a brief second with this recessed bolt.. I thought it out at work today and figured out the left handed jam bolt theory. I must admit i was nervous because i knew i had only ONE shot and had better get it right or it would be a few hundred at the machine shop..luckiliy it worked like i had envisioned so i just thought i would share to the masses.. any and all ideas are helpfull with these situations and if this helps someone i will be happy to have contributed.