Drilling out JB Weld from exhaust bolt thread?

[AMK]

The carbide cutters did the trick. I think I ordered the same set you did. They were on Amazon for about $13. I managed to grind the bolt down to where the extractor spun itself out. Now I have a bolt that is sheared flush with a 9/64" hole right in the middle of it. Not optimal, but I think I'm better off than I was (so little was sticking out that I couldn't get vice grips on it). I've ordered some left hand drill bits and I'm going to try to just bore it out till it spins out. Something tells me I'm not going to bother with those extractors again. Some work ok on an M6 bolt or so, but seized exhaust bolt? Forget it.[ATTACH=CONFIG]52398[/ATTACH]

Apply some heat to that before drilling with the left hand bit, you may get fortunate.
You look like youre centered pretty good. Step up the drills a bit at a time until either it spins out or you start seeing threads.

The carbide cutters did the trick. I think I ordered the same set you did. They were on Amazon for about $13. I managed to grind the bolt down to where the extractor spun itself out. Now I have a bolt that is sheared flush with a 9/64" hole right in the middle of it. Not optimal, but I think I'm better off than I was (so little was sticking out that I couldn't get vice grips on it). I've ordered some left hand drill bits and I'm going to try to just bore it out till it spins out. Something tells me I'm not going to bother with those extractors again. Some work ok on an M6 bolt or so, but seized exhaust bolt? Forget it.2319227677262222691-account_id=1.jpg

Using A set of double cut carbide cutters - DING DING DING WINNER WINNER CHICKEN DINNEr. I hopped on amazon and ordered a set of these for next to nothing
The two flat end cylinders did all the heavy cutting and had the tap ground mostly out within 30 mins or so.

Thanks for seeing this through and updating with what worked. I've got a broken extractor inside an exhaust bolt right now myself and was feeling very discouraged. This gives me the spit in my eye to keep chugging away. Ordering some double cut carbide cutters!

Hmm, maybe that would work. I heard diesel fuel and a dab of dawn dish soap is a formidable opponent of baked on crud. I did two thorough cleanings with mean green and was disappointed with the results.

or some old gas, and carb cleaner(spray can type). i use carb cleaner A LOT to do the majority of my degreasing. but the acid brush is the key to getting in those really tough corners

[Burque73]

Well I hope everyone had an enjoyable weekend. Mine was full of landscaping and working on the bike. Got the engine degreased and painted. Chances are I'll have to put a new head on but I wanted to try out painting with what I have. The picture I posted was of a spark plug thread chaser. Bluetooth headphones in talking to my mom and distractedly I began to strip the spark plug! Went to autozone and for $9 I came back and gave it a go. Seems like it worked. Will check for compression once everything is back together. Only to possibly take it off again and replace the head! Can you guys tell I enjoy suffering! Being young I still have the energy, time, and stubbornness to forge through situations that wisdom would deviate me from! Stay tuned this week is going to be all out motorcycle. After 5PM and before Survivor comes on.

Well, I've never watched Survivor, but I have drilled out broken bolts and retapped threads before. Spark plug repair thing from Autozone in my experience did not work. There are timeserts that others have mentioned work, but I didnt try one. They are a bit pricey.

Hope you didn't let any four letter words fly in your mom's ear during that call while working on the bike!

Well I hope everyone had an enjoyable weekend. Mine was full of landscaping and working on the bike. Got the engine degreased and painted. Chances are I'll have to put a new head on but I wanted to try out painting with what I have. The picture I posted was of a spark plug thread chaser. Bluetooth headphones in talking to my mom and distractedly I began to strip the spark plug! Went to autozone and for $9 I came back and gave it a go. Seems like it worked. Will check for compression once everything is back together. Only to possibly take it off again and replace the head! Can you guys tell I enjoy suffering! Being young I still have the energy, time, and stubbornness to forge through situations that wisdom would deviate me from! Stay tuned this week is going to be all out motorcycle. After 5PM and before Survivor comes on.

Nope, think higher.

Thread repair went well. Going to go get a stud tomorrow and while the paint cures on the engine will look at touching up the frame. Going to be packing a lot of stuff in the next week. Hoping to have a running motorcycle by the end of the week. Took my motorcycle permit written exam on my lunch break, studied the night before and on a 15 minute break, and got it registered and temp plate. I love our BMV. Test took 6 mins, registration and plate took 30 mins. All together less than one hour. Rewarded myself with Rally's. I love those fries.

[hillsy]

Stripped out the sump plug?

Anyway, how did you end up with the exhaust thread?

I'm kind of bummed it's fixed. Everyday I was checking in to see the progress and what the next step would be. What fun is next? I know, snap a oil filter cover stud off! (Just kidding, I hope I didn't jinx him)☺

Well wouldn't you know it jinxed is exactly what happened. Whoever can guess what happened here wins the smartest man of the thread award.

https://i.imgur.com/mRy0Hug.jpg

[hillsy]

The idea of the stud over a screw / bolt is that you thread lock it in and dont risk breaking it / stripping the thread in the head again when you next remove your exhaust. A dab of anti-seize on the outside threads of the stud and this issue should never happen again.

Also, did you end up getting the Helicoil in straight? This can be a problem because the bolt / stud will be skew if you didn't and it will be a PITA to get the header collet on (although you can "bend" a stud to the correct angle and then thread lock it in place).

storm 64

I'm kind of bummed it's fixed. Everyday I was checking in to see the progress and what the next step would be. What fun is next? I know, snap a oil filter cover stud off! (Just kidding, I hope I didn't jinx him)☺

Hey now! Don't go making bad Ju-Ju for my bike... There's plenty of 'whats next?' on the way. I still have electrical, and metal fab. Just bought a hobart wire welder, things are about to get interesting.

60ratrod

oven cleaner is a really nice degreaser. but if you value what ever clear coat on the engine covers might be left, it will eat it right off, along with any other paint. otherwise I think simple green and a good set of acid brushes for the tight areas would be a good way to go too. I've used oven cleaner on a lot of stuff and it works well just so long as you don't care about the paint lol

Hmm, maybe that would work. I heard diesel fuel and a dab of dawn dish soap is a formidable opponent of baked on crud. I did two thorough cleanings with mean green and was disappointed with the results.

hillsy

So I'm guessing you plan on Loctite-ing a stud in there and using nuts to hold on the header? That would now be your best option IMO.

My uncle has a way of asking a question where it really seems like he's telling me what to do, I dig it and appreciate it. So what kind of Loctite, same red stuff I used on the helicoil insert? why a stud over the stainless machine screw? In the event it snaps I can extract it easier? I've had several people tell me to go with a stud, which is what I'll probably do. Just so there isn't any more 'I told you so' moments than I need.

[hillsy]

So I'm guessing you plan on Loctite-ing a stud in there and using nuts to hold on the header? That would now be your best option IMO.

oven cleaner is a really nice degreaser. but if you value what ever clear coat on the engine covers might be left, it will eat it right off, along with any other paint. otherwise I think simple green and a good set of acid brushes for the tight areas would be a good way to go too. I've used oven cleaner on a lot of stuff and it works well just so long as you don't care about the paint lol

[storm 64]

I'm kind of bummed it's fixed. Everyday I was checking in to see the progress and what the next step would be. What fun is next? I know, snap a oil filter cover stud off! (Just kidding, I hope I didn't jinx him)☺

JJ, definitely will go that route in the future. This was a sort of stubborn pride, I'm happy with the way I went. Now I know. You've got a ton more experience than I probably ever will so this would be a huge time waster. For me though, hey cheap learning experience. Plus the weather was crappy so I couldn't shoot paint. Now I got to figure out the best way to degrease the engine for paint prep.