Exhaust Bolts Snapped in Head. FUN!!

[Yamaha3wheeler]

This bolt was turning before it snapped the head. It has about 1 to 2/16 sticking out of the head. Vice grips are tough to get on this one. I'm thinking I will need an extractor bit. The 5/64 bit seems like it would be a good fit. Opinions?

The other was frozen completely. It has about 1/4 inch sticking out now that the head is gone. I can definitely get vice grips on this one.

Should I use a head gun? How long do I hold a head gun to it? I do not want to melt the alum. What wattage?

I used pb blaster but it didn't work too well.

Should I just go with a bolt extractor?

Anyone been through this? How would you handle?> Any advice would be so greatly appreciated.

Thanks!

[madmass]

I had that issue a while back on my 110. Found this stuff called knock'er loose by CRC. Used a pair of snubbed needle nose vice grips and a small propane torch. They came out pretty quick. The knock'er loose worked better than any product I've found yet. Just added heat on and off till they broke loose.

[ebaccm26]

Don't worry you won't melt anything lol. You will need a torch though, I can't imagine a heat gun would be sufficient. Use your judgement and heat it until you think it is hot enough, and then heat it some more. Make sure you are heating the head at the base of the stud and not just the part of the stud that is sticking out. I have never had a stud that was sticking out enough to grab that did not come out with the use of heat.

Just drill the other one out and tap the hole.

[ironchop]

too bad you don`t have a welder....or do you?

with that much sticking out, at work we find a nut with a slightly larger ID than the stud, slip it over the stud, and weld a dab right in the center of the nut and stud. when it cools off, grab a wrench and take it loose. I would also use penetrating oil soak beforehand as mentioned above just as an additional measure

[Yamaha3wheeler]

I have a 1000 degree heat gun. Will that really not do the job? I'm afraid to use a torch as I wouldn't want to melt the head. I know that the torch I have would melt a coke can within a second. Of course, the head material is much thicker.

I would rather be safe than sorry , but if I'm just wizzing in the wind so to speak, I'll use the torch.

[Yamaha3wheeler]

I have a mig welder. I think I'm going to weld a nut on it.

Anyone have any tips on how to weld on a nut to the stud.

Never done this before. It is as easy as holding a nut a the end and tacking it?

I need as many details as possible.

Thanks!

[Samjp22]

Do as ironchop said about welding it

[trikeguy2014]

I use easy outs work for me typically it's just a type of bolt extractor... You drill a hole in the bolt then just turn the easy out in reverse to remove the bolt

[Jmoozy27]

If you don't want to use a cutting torch or rosebud, I often use a propane torch to get the job done. That will never melt the head. Where in Louisiana are you?

[onformula1]

I have a mig welder. I think I'm going to weld a nut on it.

Anyone have any tips on how to weld on a nut to the stud.

Never done this before. It is as easy as holding a nut a the end and tacking it?

I need as many details as possible.

Thanks!

Before you weld a nut on, tap the stud with a roll pin punch (Flat round headed punch) a few times that with break it loose a bit, don't pound and damage the threads.

With a 1 1/8" sticking out just clean up the end of the threads, thread a nut down till it bottoms (correct size) and weld the nut to the stud at the top, to the inner part of the nut, use deep penetration don't just tack it, then use a box ended wrench or if you didn't make a welding mess a socket it unscrew it.

Now go get that helmet on.

[Frankencelery]

You can hold a propane torch on that head for 5 minutes and it won't melt it! I've done this every possible wrong way that you can, so I can certainly say what doesn't work. It DOESN'T work to heat the stud only. That just makes it soft and it will twist off even more easily than it probably already will. And me and easy outs have a rocky history. I think it's 50% good, 50% breaking the easy out in the hole and now I have a hardened piece of sh*t inside the hole where the stud used to be.

[Chopsaw]

We used to use reverse drill bits , that cut counter clockwise . In effect turning the broken bolt in the direction needed to back it out as you drill the hole .

[jb2wheels]

...And me and easy outs have a rocky history. I think it's 50% good, 50% breaking the easy out in the hole and now I have a hardened piece of sh*t inside the hole where the stud used to be.

Me too. I threw all my EZ outs away after about the 3rd round of this. Never again. I'd rather grind them off and drill them out. Even if it's off center I can make it work but I'll never get that EZ out chunk out.

I like heat and reverse bits.

I've tried welding a nut on but I suck as a welder so that's hasn't worked.

[Dirtcrasher]

If you can't get it out, don't ruin the hole; Send it to me and I'll get it out on the Bridgeport milling machine for a fair price.

[YamaBoss]

Me too. I threw all my EZ outs away after about the 3rd round of this. Never again. I'd rather grind them off and drill them out. Even if it's off center I can make it work but I'll never get that EZ out chunk out.

I like heat and reverse bits.

I've tried welding a nut on but I suck as a welder so that's hasn't worked.

Dad always warned me about easy outs, heard lots of stories of guys at work breaking them off... Never going to try it and would never tell anyone to use one.