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rusted in exhaust bolt

jim mac

jim mac

Cruisin' Guzzisti
GT Famiglia
Joined
Mar 13, 2009
Messages
132
Location
Edinburgh, UK
I've got a rusted in exhaust stud that has stripped its threads and is rock solid. I have tried light oil/acetate mix, diesel, heat and a bit of bashing - no movement at all.

Even tried cutting new thread but no luck.

i dont have facility to weld a nut on top

Any suggestions on getting it out
 
Last resort is to cut the stud off flush, center punch it, and drill it out. I once did that on a Buell. I used a drill bit that was smaller than the stud, and kept switching to bigger and bigger drill bits until I could remove the threads of the stud from the hole. That actually left the threads pretty intact, and I was able to clean them up with a thread chaser and screw a new stud in. But you may need to re-tap the hole.
 
You're a lucky man to get an exhaust stud center punched accurately enough to continue
oversize drilling until the threaded area is reached . If you miss , it's usually a head off and
machine shop visit (which may be your best choice now ). Peter
 
I have removed exhaust flange studs by carefully heating the stud near the head with a propane torch, quenching with spray penetrating lubricant, and tightly gripping the stud from the side with vice grips. Then I wiggly back and forth from clockwise to counterclockwise loosening it slowly. Don’t try to force it out with a single twist as you’ll likely snap the stud. Back and forth, breaking the galvanic bonded metal and threads slowly and gently, and it will eventually give way and come out.

When it won’t move anymore, I repeat the whole heat, lubricant, process again.

It will come out. Patience and carefulness is rewarded here.

Good luck!
 
Last edited:
Moto-Uno said:
You're a lucky man to get an exhaust stud center punched accurately enough to continue
oversize drilling until the threaded area is reached . If you miss , it's usually a head off and
machine shop visit (which may be your best choice now ). Peter
Click to expand...
I think it was more about being careful and precise, but being lucky never hurts.

I had tried what Scott suggests, and that failed. Eventually, drilling it out was my only option left without pulling the head. If it went south, I would have had to pull the head. So really I had nothing to loose.
 
^^ I might suggest that if it goes wrong , you may very well increase a machine shops price to correct .
Exhaust studs are a bit*ch at the best of times . Good fortune to anyone that tries and here's hoping for
the best outcome ! Peter
 
I created a little cup from blutack around the bolt and filled it with acetone/light oil mix which has worked for me in the past. Left it soaking until today and tried again

A bit of heat, grips onto it and absolutely nothing, no sign of movement at all. Cup back on and diesel dropped in to leave for another day or two. Weather is pretty poor so I am not going to try to rush it or get physical.
 
Another thing I do is give the stud a few good whacks with the flat face of a hammer right on the end of the bolt, applying the force directly towards the bolt and towards the head.

This also helps break the galvanic bond between the stud and the head.
 
Failed totally to get the sucker out. Its going to need a welding torch to heat it up.

Currently all bolted back up until I can find someone with the heat capacity
 
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