Exhausting Exhaust studs

[procamper]

Well, my BRAND NEW (to me-thanks ebay!) 4>1 supertrapp finally came today!

so, out in the garage I was, pulling off the old system. 7 of the 8 bolts come off the head no problem. The LAST ONE decides its 'to good' to behave and it snaps about 1/16" into the head. I'm a little miffed, but fortunatly I've got a fairly well stocked garage with a complete set of EZ outs. I centerpunch the busted stud, drill my hole, and procede to break the STUPID EZ off in the hole!

oh, btw, of course this happens to be the one stud thats partially behind the downtube of the frame, so drilling a straight hole is sketchy at best.

so, out comes the next larger ezout and drill bit. I manage to get a hole drilled next to the busted one, which I promptly procede to break off the other ezout in!!! ARRRGH!!!

So, as I see it, I can try to borrow a carbide bit at work tommorow and try to drill out the ezouts, but if that doesnt work, is my only option to get a new cylinder head??

anyone else ever have this problem?

HELP! now none of my three bikes run!

[mitch]

studs

I had 3 studs break off in my xj head, so i bought some 3/8 nc threaded rod at canadian tire and drilled out all the exhaust bolts and replaced them with 3/8 studs. I bought some nice chrome cap nuts to finish them off. My plates on my 4 into one are flat so it worked great and they are a lot stronger studs . ps. i put lock tight on everthing dont know if i shoulda . good luck took me 5 hrs .

[Bud Manley]

Similer event occured while I was trying to take the front quarter panel off my wifes jeep last night. For some reason regardless of what I work on there is always one bolt that breaks off or strips out.

[mitch]

Forgot to mention

BTW i didnt remove the engine to drill the head i just unbolted it so i could move it enough to get past the down tubes hope this helps and good luck regards DOUG M

[s38310]

I feel your pain, been there many times. I would try a left hand drill bit if you still have room but its very important to get a straight run at it. If it ends up you have to pull the head then either purchase a helicoil kit (usually available at various parts stores) in the stud size you need or find a machine shop that can install one for you. Usually the cost is reasonable. A head replacement should not be required. Good luck, Craig

[nashville_bill]

Another last resort suggestion: Weld a bolt onto the broken stud and twist it out with a wrench.

[procamper]

well, I pulled the head off and its over at the machine shop now... They're going to EDM it. Its a good thing ive got a good relationship with them-- thier doing the work for two of my mom's fresh apple pies

thats especially important considering i just ordered 100 dollars worth of gaskets to put everything back together