PO botched drill atempt, what to do?? HELP!

[scaylabs]

Considering I only had 5 bolts holding the exhaust to the head to begin with I guess I'm kinda lucky that 2 of the missing bolts were just out of plain laziness on the PO's part.

This is the broken one, including a previous attempt by some PO at drilling it out:


Heli-coil?
Ideas??

[bluewool]

I am having trouble figuring out what is going on in the photo. It appears that the PO missed the centre of the original stud, drilled half of it out and tapped into the head and the original bolt/stud? Is that what's going on? IIf that's the case I have no idea what to do, other than some hillbilly solutions I am sure you've already thought of.

[makenzie71]

It looks like the bolt broke off inside the head and the guy tried to drill it and the bit walked off.

I would just replace the head. There's lots of them out there.

[scaylabs]

I don't know either. He missed the center for sure and half of the old bolt somehow came off. If I could get the other half off I'd be in business in no time as there's probably plenty of thread in the bottom. There is some thread left on top but not enough to grab.

I'm all for hillbilly solutions!! Please do tell, as I don't have much experience.

[bluewool]

grind it flat, centre punch it and drill it out. That's about it.

[Tom R]

Or just live with 7 bolts.

[1980GS1000E]

Considering all the muck that is visible between the head and cylinder, you want to pull that head anyway.