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exhaust stud extraction - alloy head

Posted: Tue Aug 07, 2018 7:54 am
by barker
My exhaust studs on my alloy head scooter are refusing to undo.

I know they are a sod on a cub with an iron barrel but on an alloy barrel is there a easy way to get them out before I have to drill and tap?

I saw on YouTube, a guy heating the barrel with a flame then extracting the bolts. Is it that easy?

Re: exhaust studs

Posted: Tue Aug 07, 2018 8:34 am
by Capitano
That's how the exhaust nuts and studs came out of my 18 year old CBR1000 that hadn't been touched from new.

Not by me, mind. I took the view that I'd be better off booking a day's work and paying half to my local independent bike shop to do it, rather than spend 2 days doing it badly myself. 8-)

Re: exhaust stud extraction - alloy head

Posted: Tue Aug 07, 2018 11:38 am
by Diesel Dave
Cub exhaust studs are in the alloy head.......

You need to get it as hot as you dare without melting the alloy or setting fire to the rest of the bike. That’s why welding a nut onto the stud remnants works as it gets the stud red hot but shouldn’t melt the alloy as there’s not enough time for the alloy to overheat.

Re: exhaust stud extraction - alloy head

Posted: Thu Aug 09, 2018 6:09 pm
by barker
made a start on the job , has anyone got any tips as how to drill the studs straight

Re: exhaust stud extraction - alloy head

Posted: Thu Aug 09, 2018 6:25 pm
by JOHNBOY
bolt the head on to a pillar drill rotate the plate to suitable angle bobs y uncle

Re: exhaust stud extraction - alloy head

Posted: Thu Aug 09, 2018 8:40 pm
by barker
have not got a pillar drill , plus engine is still in the scooter

Re: exhaust stud extraction - alloy head

Posted: Thu Aug 09, 2018 10:18 pm
by JOHNBOY
good luck

Re: exhaust stud extraction - alloy head

Posted: Fri Aug 10, 2018 7:09 am
by davebike
Head and barrel off try heat and stud extractor
Next weld lump of steel to stud reheat to cherry red keep trying !
when stud snaps bolt to pillar drill or better a mill and use a bull nosed milling cutter !

Far from easy job
MUCH easer if
1 don't use stainless studs
2 always use copper or alley slip on studs

Re: exhaust stud extraction - alloy head

Posted: Fri Aug 10, 2018 8:16 am
by andyk1k
Can l post,pistol handheld drill =scrap !

Re: exhaust stud extraction - alloy head

Posted: Fri Aug 10, 2018 1:55 pm
by Tranberg
After you've broken the brittle stud extractor, next step is this guy: Spark erosion of broken tap

[youtube]https://www.youtube.com/watch?v=8VvLJWkFGIw[/youtube]