Snapped bolt

[Jonny_L]

I've just fitted my new remus headers (thanks ynotbiker ), and managed to snap one of the studs in the block at the exhaust port

Good news is there's quite a bit of thread sticking out to grab onto, but I can't get my mole grips in there and don't really fancy welding a nut on in case i melt something.

Oh and the other good news is it's on the left so I can get at it by only taking off the short header pipe It's popping a bit though as it would, so I don't really want to ride it like that much.

Anyone got any ideas before I give up and take it to vines?

 

[patzx12]

Hi, If you have a bit of stud sticking out it will be easy for someone with a bit of engineering skill. First of all give it plenty of WD40
I would drill it exactly down the middle with a good quality drill and use an extractor, this has to be a really precise hole if you run off it will chew up the alloy. Start with a 2mm drill a bit at a time checking all the time that its square.
Or sometimes I would T.I.G weld a nut onto the remaining stud but to do this I would disconect to battery and the ECU.

 

['Nuffsaid]

Or .... of you can get a junior hacksaw in there, cut a slot across the top of the bolt enough to get a large flathead screwdriver (Ideally T-bar) onto it.

 

[Jonny_L]

Good suggestions. I can't get a hacksaw in there unfortunately, though I should be able to drill it and put a stud extractor on there. I tend to find them a bit touch and go but I suppose it's worth a try. I wish I could just weld a nut on but I think I'd end up messing up the engine paint and god knows what else in the process

 

[northengit]

Good suggestions. I can't get a hacksaw in there unfortunately, though I should be able to drill it and put a stud extractor on there. I tend to find them a bit touch and go but I suppose it's worth a try. I wish I could just weld a nut on but I think I'd end up messing up the engine paint and god knows what else in the process

It's been said before, but be very careful using these extractor/easy out things... their so bloody hard and fragile' snap one of those in the stud hole and you have more trouble.

Try the weld option (making sure you disconnect the sensitive stuff).. donn't just rely on the nut being blobbed on , you need to try undoing it while you still have lots of heat in the stud and head.

Be prepared to whip the head off though and give it to the pro's to drill out. safest.

 

[GIMLET]

Have you enough thread available to fit on two nuts, tighten them against each other soak it in release oil and see if it will move by turning the lower nut.
Worth a try.

 

[GOATIEBABY]

Stud Extraction

I would recommend you try one of these instead of the drilled extractor idea as getting the hole in is not easy and the easyout extractor often snaps leavimg you with all sorts of problems. http://www.machinemart.co.uk/shop/product/details/pro57-4-pce-stud-extractor-set.

 

[THE DOCTOR]

I'd also go the extractor route.

I've lost count of the times this baby's got my out of a tricky situation. Had it for years.

These eccentric cam types just grip the stud tighter the more you turn it.

 

[zerocool]

ive never seen one of them, how does it work.

 

[Hookster]

I'd also go the extractor route.

eccentric cam types just grip the stud tighter the more you turn it.

You need a fair bit of room to work with them but yes they're worth their weight in chrome vanadium.

 

[Jonny_L]

Well, that's buggered it Stud extractor didn't work, I think it just expanded the stud and then wore out. It's pretty messed up now, not much more I can do I don't think.

Oh the 2 bolts thing didn't work as there's not quite enough thread left. I reckon those other stud extractors could have helped too.

Considering this is a 3 year old bike and I'm used to working on 40 year old cars, I'm amazed to say this bolt is up there with the best of them! That's exhausts for you

Oh well. I can't really be dealing with taking the head off right now, best get it booked in I suppose

 

[patzx12]

Hi post a picure if you can

 

[autogs]

snapped bolt

jonny,what you need is an external socket type removal tool,i bought 2 sets from snap-on,saved my life loads of times since i got them,tour not to far from me if you want to try them,pm me as they are at work(byfleet) these tools are very slim unlike cam type which you wont have room to use in your case

 

[Jonny_L]

OK, just so I'm not going completely mad... This thing is screwed in in the normal righty-tighty way isn't it? It feels like they've used a threadlock not yet known to mankind

That's really kind of you autogs, I've just had a look at the tool you mean, definitely something I'll be putting on my wish list Unfortunately there's not really any thread left now though, a mate of mine had a play with the mole grips earlier and trashed the thing completely, it doesn't even look like a stud any more Still didn't get it out either.

I've put the exhaust back on now so I can ride it to vines, but I'll have a play again on monday. It's not likely, but if I can tap a thread back on the thing somehow I'll definitely give you a shout

 

[cusi]

Johnny sorry to hear about your predicament, must say I am impressed by the amount of help and advice that has been offered.

Cos I am a nosey b'stid did you snap the stud when taking off the nut or tightening it up?

 

[judge]

Jump on the bike or recover it up the A3 to St.Eptoe, he's had an easy weekend as the snapped stud I left him with came out in minutes and it should have taken all day with stud extractors, tap & dies and loads of broken drill bits in his new drill.

He'll thank you for taking his mind of Arsenal caning his boys later

 

[karnevil]

I have to do a lot of broken stud/bolt removal in the course of my work.Im my expirience the easi-outs never work,if a 10mm shaft breaks while undoing it how will reducing it by 1/3 work?(thats effectivley the size of the easi-
out)The stud/bolt is already tight so forcing a lefthand taper screw into a hole you have made in it only makes it tighter!
The next best way is with the external type extractors like shown on here or sadly have it drilled out by someone who can pick up the centre exactly and drill out the core of the thread then pick out the remains.Alternativley it could be spark eroded if the easi-out is broken in it.I canot spark errode.
I know you are a distance away but if you can renove the head I would be happy to drill it out for you,F.O.C.if you could get it to me and back to yourself.
Cheers Andy

 

[bowser]

exhaust tip

Here is a tip when you put the new stud spend extra money and get stainless studs or studding and then use brass nuts, it is impossible for brass to rust itself to ss, and if anything strips its the brass nut. I try and use aircraft nuts, they are anti vibration but dont use nylon as nyloc nuts do. Saves a world of hurt further down the line, even if the stud gets stuck who cares the nut comes off and you dont destroy the thread on the stud

 

[Jonny_L]

Johnny sorry to hear about your predicament, must say I am impressed by the amount of help and advice that has been offered.

Cos I am a nosey b'stid did you snap the stud when taking off the nut or tightening it up?

I agree, you lot aren't half a helpful bunch, thanks!

It was while I was undoing it. In my defense I didn't go at it with a breaker bar or anything, it was pretty weak. I probably undid the other bolts with more force!

karnevil, thanks very much for the offer, I'm sure I could post it to you otherwise.

With a bit of luck it won't come to that, I'm gonna have a careful play with the dremel tomorrow I think. It looks like the last option left to do myself is to try to get a couple of decent flat edges and have another go. I should think anyone who'd want to drill it out would want to grind off the mashed up bit anyway so I suppose it wouldn't hurt now.

Bowser, oh yes, I will be taking every precaution available to myself if (hopefully when!) I get this little bugger out!