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  1. #1
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    Default Broke down and busted. Broken exhaust stud turned into nightmare.

    Hey guys.

    So like a scene from family ties, my buddy was trying to
    help me with wrapping my exhaust. A simple task that you'll soon see
    went horribly wrong.

    We had removed and completed the rear pipe, I had to depart to pick up
    other parts for another customer. My associate assured me he could
    handle the other front pipe. I left.

    I returned to a slumped over, half suicidal friend. I exclaimed.
    "what's wrong", he replied. Man I fucked up.

    When removing the front pipe. Apparently the first stud unscrewed from
    the head. I.e. the nut didn't budge. The stud freed. When removing the
    second bolt. It snapped. Right at the exhaust port. And he explained the he
    tried drilling and tapping. Unfortunately from a 45 degree angle to
    the original bolt ( almost sideways ). It literally took everything I
    had not to physically assault him. I understand I had trusted him to
    do it and that's my problem. But I would think when something went
    wrong. You would stop.

    Jesus.

    Now I have half a drilled bolt in a half way angular drilled hole in my head.

    I'm not sure what to do besides buying a new head.

    Thoughts?
    Last edited by theangus; 07-31-2012 at 7:55 AM.

  2. #2
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    If you were local I could help you out. But 1000 miles is just over my mobile working limits so:

    Find a competant mechanic or machinist with a lot of experience and he can get it out. Possibly even an aircraft A&P at a local small airport. Those guys have the smallest coolest drills and grinders you will ever see. You will more than likely need at least a heli-coil in that hole but it can be done. If access is tight be prepared to maybe have to pull the engine or the head. Basicly get ready to bend over and pay the man. It could take a couple hours but they should be able to drill straight in progressively chewing the bolt out.

    Remember, competant doesn't mean the guy that's doing it the cheapest. Good luck.

  3. #3
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    best bet would be to pull the head off and bring it into a machine shop or similar that can secure it to a milling machine or heavy duty drill press that doesnt shake
    then they can properly drill it out
    and fix and repair the hole
    or hunt around for a used head in good condition
    evo parts are cheap enough that it might cost you as much in labor to fix yours as it would to find a good used head

  4. #4
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    Killer advice guys and I really do appreciate it. My concern is after the labor costs, shipping, actual labor, I might as well just buy a new head. but like everything else, should I get two? will running two diffrent heads kill the bike?

    Maybe im crazy...

  5. #5
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    Is there enough of the broken stud exposed to weld a nut on to it?

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    I believe JIMS sells a jig for drilling them out. But alas you still have the problem of the extra hole. If it were me I'd price the repair of that head, and depending on price I'd look at some new heads from Branch or somebody else. Shit Branch may still do an exchange with them. If they are stock HD heads then I don't really think it'd be a problem to run something off of a different bike.

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    how about some pics of what your working on? ive drilled countless studs out of truck heads, working in a ford shop you learn to use a angle drill pretty damn good.

  8. #8
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    Quote Originally Posted by roush360r View Post
    how about some pics of what your working on? ive drilled countless studs out of truck heads, working in a ford shop you learn to use a angle drill pretty damn good.
    Ill post pics in the morning. Just removed the heads tonight...

    Thanks a ton guys.

  9. #9
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    if you have stock heads and replace the bad one with another stock head used or new you wont have a problem

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    Quote Originally Posted by SyndicateChoppers View Post
    if you have stock heads and replace the bad one with another stock head used or new you wont have a problem
    Thats actually what I did. Ordered a set of heads that were cold tanked, resurfaced, and the seats and valves resurfed as well... $225

    Hope I didnt get screwed.

    Any thoughts on being able to repair the old one to sell them?

    Thanks!

  11. #11
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    need some pics!

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    Hey guys.

    Sorry to be tardy to the Pics party.

    Included are three images of the drilled hole. they arent the best quality.

    but as you can see there is still some remaining bolt, in the completely sideways drilled and tapped hole.

    also on a side note.

    easiest way to get the intake manifold off???

    Thanks!!!!

    p.s. Im trying to repair this head to sell to compensate for my new ones. think im asking a bit to much?
    Attached Thumbnails Attached Thumbnails DSC00047.jpg   DSC00048.jpg   DSC00049.jpg   DSC00050.jpg  

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    Looks like machine shop work to me. Needs to be straight and true to the world before augering in to that hole. If there's enough meat around the hole it could possibly handle a "Twinsert" type repair...basically a ID/OD threaded plug. Good luck man!

  14. #14
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    Would I structurally damage the head If I filled the hole with a MIG welder? then grind, drill and tap again?

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    Looks like you could probably put a bolt up to that broken one, and weld it to it. Then twist it out. Then you could have the hole drilled out bigger, filled with weld, drilled and tapped.

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    i hope you're mates got his wallet out too, for not knowing to stop when he runs out of talent on someone elses bike.

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    Quote Originally Posted by theangus View Post
    Would I structurally damage the head If I filled the hole with a MIG welder? then grind, drill and tap again?
    yes uou cant mig weld aluminum unless you have a spool gun setup with your mig and they are usually hogh dollar
    i would try welding a longer bolt onto the broken stud first then heating the area of the head around the stud and see if it will break loose and come out

  18. #18
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    Quote Originally Posted by darkdesign View Post
    i hope you're mates got his wallet out too, for not knowing to stop when he runs out of talent on someone elses bike.
    He's MIA now... Really shitty that this all happened when I wasnt there to "Oversee". Trust me Im pissed. didnt even get a sorry.

  19. #19
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    Quote Originally Posted by theangus View Post
    He's MIA now... Really shitty that this all happened when I wasnt there to "Oversee". Trust me Im pissed. didnt even get a sorry.
    if he's a good friend I would chalk it up to shit happens man,
    bikes come and go good friends are hard to come by,
    if he's just someone that your not that close with then yeah I would make an issue out of it

  20. #20
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    looks like he almost totally missed the bolt. if you cant weld somthing onto the broken stud you could pry use a very thin carbide bit and go in the hole he already drilled and grind the bolt like in half then kinda chip it out

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