Exhaust header leak,looking for fix tips...

[UncleMike]

Well they all came out super easy. 2 of them too easy they broke in the head.

Flush or with some stud still sticking out?

[Mr.Mom]

One is slightly out by about a thread the other one is flush to slightly inset by a thread.

[MK3Brent]

Well, enjoy the fresh hell you're about to go through.

[Mr.Mom]

Bought an extractor from AutoZone. Just as I was going to give up, didn't want to break the tool in the head, I gave it one more turn and the bolt started turning. So 1 down 1 to go.
In the mean time my gas tank rolled off on to the cement floor At least this bike thing was given to me

[Grimly]

Yeah, go easy with the extractors - left-handed drill bits are your friend for these things. I now hate extractors, with some fierceness.

[Mr.Mom]

Its always something. The other one is hard to get to because the frame bar is in the way. Not sure how I'm going to drill a hole in the center of the bolt.

[Grimly]

The ones behind the frame are often the ones that break for some weird reason.
I'd use one of these - I have similar, this is just an illustration of what's available. http://www.amazon.com/s/ref=nb_sb_no...0drill%20drive
I have a small Makita battery drill that's very slim, too. Old but good in this tight situation.
<edit>
Just refreshed my memory by having a look at one I'll have to do - the forks will be off when I do it, so it's much less hassle. It looks as though I'll not be able to get to this one with a slim drill (#3 bottom bolt) as it's too tight next to the frame tube, but a long cobalt drill will do the job.
Example: http://www.phantomdrills.co.uk/shop/...s_%28hss-co%29

[Mr.Mom]

Thanks grimly for the ideas. I ended up getting a Irwin 6" bit extender for under $4. So far I am 1/3 through the bolt.

[Mr.Mom]

Any ideas how to get a bolt out that won't budge with an extractor? I drilled all the way through the bolt, used the extractor and the extractor broke off. Drilled the extractor out...now what?

Thank you

[MK3Brent]

Got pictures?

[Mr.Mom]

The exhaust bolt with a hole in it. Right at the very end the drill wobbled and the first thread got all fudged up.

[Grimly]

If it were me I'd get some lefthand drills and go up small increments until the remains of the bolt unpick.
The extractor coming out was a dodged bullet - forget them.

[UncleMike]

I'd be drowning it in PB Blaster.

[OldVet66]

Drilled the extractor out...now what?

Thank you

Drill through with a slightly larger drill. If it gets thin enough it will start to move. If you are careful to keep it straight any small damage can be dressed up with a tap. The left hand drills are an extremely good idea, will probably catch and screw the the rest out when it gets thin enough. Might be a good time to try out SeaFoam Deep Creep and let us know how it works.

[Mr.Mom]

Well looks like it will have to be retapped. Any suggestions on this as far as size etc.? Should I use a heli-coil instead?


Thank you