WonkoTheSane
Well-Known Member
I have a 1991 VMax that I'm replacing the downpipes on (rusted original one) and I have run into some trouble. I'm running out of ideas so any thoughts would be appreciated.
Out of 4 studs, the first one came out with the hex nut (probably the best possible outcome), the second sheared off level with the collar and the other two the nuts came off as expected.
The problem is that both collars were stuck on the internal studs (nearest the centre of the bike). While trying to wrestle the pipe off the broken stud (after lots of WD-40, some heat and hitting it quite a bit), the stud broke again, this time just inside the engine.
My friend had a stud-removal kit (tapered bit with reversed thread on it) so we drilled a hole in the centre of the broken stud and applied the stud-remover....
Which snapped off, leaving itself (hardened steel) right in the middle of the stud, and nothing we throw at it has been hard enough to drill it out.
We've made things worse by trying to drill it out, or around it with a smaller bit and are now kind of desperate. Funds are in short supply and I really don't want to have to remove the whole engine and take it to a machine shop (way beyond my comfort zone) to try to solve it.
The other issue is that the other collar is still stuck fast onto the innermost stud (but moves a bit on the outer one). Any bright ideas for getting that to shift? We've tried heat and a candle, penetrating oil, hitting it, levering at it (we've taken the radiator off to get better access) and have stuck there, too.
Out of 4 studs, the first one came out with the hex nut (probably the best possible outcome), the second sheared off level with the collar and the other two the nuts came off as expected.
The problem is that both collars were stuck on the internal studs (nearest the centre of the bike). While trying to wrestle the pipe off the broken stud (after lots of WD-40, some heat and hitting it quite a bit), the stud broke again, this time just inside the engine.
My friend had a stud-removal kit (tapered bit with reversed thread on it) so we drilled a hole in the centre of the broken stud and applied the stud-remover....
Which snapped off, leaving itself (hardened steel) right in the middle of the stud, and nothing we throw at it has been hard enough to drill it out.
We've made things worse by trying to drill it out, or around it with a smaller bit and are now kind of desperate. Funds are in short supply and I really don't want to have to remove the whole engine and take it to a machine shop (way beyond my comfort zone) to try to solve it.
The other issue is that the other collar is still stuck fast onto the innermost stud (but moves a bit on the outer one). Any bright ideas for getting that to shift? We've tried heat and a candle, penetrating oil, hitting it, levering at it (we've taken the radiator off to get better access) and have stuck there, too.
