Broken exhaust bolts!!!!!

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[fatblokeonbnadit]

got a broken off bolt  in me spare gsxr 1100 engine, so time to sort it,,,,
Lots of people seem to struggle with this so here an easy way, BUt you have to have a bit sticking out with some thread on, no good if its snapped flush..



first you need to make a drill guide, a bit of 12mm ally bar from B&Q with an 8mm thread through it for starters..and a couple of short m8 allen bolts..



bang a thread through the ally bar and drill a hole through the allen bolts with some decent small drills, I used 3mm and 4 mm , and made two adaptors for the guide.








Next after cutting the stripped bit of thread off of the end with me dremmel, screw the adaptor onto the stud, and screw the smallest guide into the end,




Using the guide carefully drill the stud with the smallest drill, you need good drills B&Q's wood drills aint going to do it.. once thats through put the bigger size guide in and enlarge the hole,,




you can now use bigger and bigger drills until you get rid of the stud, up to the tapping drill size for an m8 which is 6.8mm.. then retap the thread, Voila simples........

[cowasaki]

I had to do this exact job on my lads 125 last month and this would have been much better!  I ended up flattening the stud and centre punching it then using a cobalt drill bit and cutting fluid.  I was lucky and got it bang on but this would most definitely made the job simpler.  It's a shame that most people wouldn't be able to follow the guide through lack of a lathe to make the parts.  Maybe you should knock a few kits together :D

[fatblokeonbnadit]

chineese lathe coast me £300 10 years ago, saved me hundreds, also there are hundreds of small engineering firms all over the place, thye will knock this up for a few quid?? or find someone who works in a big factory they always have engineering workshops..

[cowasaki]

chineese lathe coast me £300 10 years ago, saved me hundreds, also there are hundreds of small engineering firms all over the place, thye will knock this up for a few quid?? or find someone who works in a big factory they always have engineering workshops..

A lathe is on my shopping list.  I'm just building my man cave again and looking to purchase a metal folder, hydraulic bender, compressor and a lathe/milling machine......  I kept all my hand tools plus the welder, tower drill, bench grinder, bench polisher etc but now I'm kicking myself that I got rid of the compressor, parts washer and stand alone sand blaster.  It'll take a while to get everything back again.

[Paulos]

+1    Yeh I'm at the soaking stage now but have two possible more to get out, those guides would be nice to have

 

[fatblokeonbnadit]

+1    Yeh I'm at the soaking stage now but have two possible more to get out, those guides would be nice to have

 

you can borrow them if you like??,   how much thread have you sticking out?? got a picture

[Paulos]

Thanks for the offer, I might take you up on that but I have asked a mate who is buying one of these next week..... http://www.ebay.co.uk/itm/200986144622?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

only difference I will do to your method is use Left handed drill bits in the hope they come out while drilling possibly save tapping them out again

both are almost level with the top of the flange (one on the bandit so far and one on my GN250)

[dharry]

got a broken off bolt

don't you have one of those?

http://www.ebay.it/itm/40410512-8PC-Broken-Damaged-Screw-Stud-Bolt-Remover-Extractor-Easy-Out-/281303090213?pt=UK_Hand_Tools_Equipment&hash=item417ef88425&_uhb=1

I think it's easier... not?

best,

DH

[hjp1968]

If one of those snaps off you are completely buggered!!!!

[fatblokeonbnadit]

don't you have one of those?

http://www.ebay.it/itm/40410512-8PC-Broken-Damaged-Screw-Stud-Bolt-Remover-Extractor-Easy-Out-/281303090213?pt=UK_Hand_Tools_Equipment&hash=item417ef88425&_uhb=1

I think it's easier... not?

best,

DH

havent usec one of them for years since I snapped one off in an lc350 crankcase bolts, they are too brittle, especially as those are a set for a lot less than i pay for a good drill bit

[dharry]

I snapped one off in an lc350 crankcase bolts

...ouch! But if you use a good set of tools, I think it's a rare event.
If some of the bolt is outside, you can also try one of these:

http://www.ebay.it/itm/Yato-professional-roller-stud-extractor-set-4-pcs-YT-0620-/181165076642?pt=UK_Hand_Tools_Equipment&hash=item2a2e47b0a2&_uhb=1


best,

DH

[cowasaki]

I've used them and they are rubbish. I have decent stud extractors but you need more stud showing.

[gsf600]

May help if you can't make them
http://www.ebay.co.uk/itm/BZP-Stud-Connectors-Long-Nuts-Threaded-Bar-Rod-M5-M6-M8-M10-M12-M16-M20-/271213444072?pt=UK_DIY_Material_Nails_Fixing_MJ&var=&hash=item3f2594bbe8

[Paulos]

May help if you can't make them
http://www.ebay.co.uk/itm/BZP-Stud-Connectors-Long-Nuts-Threaded-Bar-Rod-M5-M6-M8-M10-M12-M16-M20-/271213444072?pt=UK_DIY_Material_Nails_Fixing_MJ&var=&hash=item3f2594bbe8

perfect thanks, I will try these

[fatblokeonbnadit]

...ouch! But if you use a good set of tools, I think it's a rare event.

Good tools, not me I just use any old junk i find in my tool box
And the rerason there are 2 missing is one twisted and one sanpped.