Broken Engine Studs Help Please

Ive always been a fan of stainless fasteners but the GS proved the error of that. One of the side case frame mounting blocks has a corroded thread which just sheared off the stainless bolt. The alloy threads had corroded badly and as Aluminium oxide is a larger volume than bar aluminium it just jammed the threads. I managed to drill it out the broken bolt but the threads were clearly chewed away by the corrosion. Its now got a new bolt and good quality antiseize paste but I suspect its unlikely to stop the corrosion.

Rather than replace fasteners with stainless it would be better to invest in a plating tank and zinc plate the bolts. The zinc is sacrificial so will be depleted but can always be re plated. There will also be better plating options.

Basics
http://en.wikipedia.org/wiki/Galvanic_corrosion

Plating options (towards the end)
http://www.aluminiumdesign.net/desi...osion-resistance/#toc-aluminium-and-fasteners

Edit
I also prefer to use carbons steel nuts on stainless bolts because they dont gall or shake loose. But they do need a very good quality plating. Also dont use plated washers unless you really ant to see some rust stains. Zinc plating the stainless threads (if not the visible head) is probably a better option.
 
Yup. It's a pain. Currently have a broken bolt in the front of mine where I'd a Cymarc crud catcher. The bolts are 50 or 55 long?
They were put in the day I got the bike new with ROCOL anti seize supposedly for stainless in alloy. Not cheapo 'coppaslip'. But, leave it there for 2 years and it snaps off. It got Würth penetrating fluid, heat, more penetrating and ultimately it sheared.
If its raining at the weekend ill be in there with the Dremel and a diamond burr. M8s are easy. M6 concentrates the mind somewhat. In future stainless will be removed every 6 months, cleaned and put back.
 
Thank You All

I went in to the dealer where I bought the bike (Shirlaws Aberdeen) and if I can't remove the studs myself they will take them out for me, which I think is very decent of them.
So thank you everyone for all your advice, all very useful, I'll post some pics when I'm finished.
Cheers
Colin
 


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