15 CVO RGU 60K, flange stud snapped inside the mounting hole, front header outside hole on the rt, had to look in there with a scope as you cant see it from just looking at it, any advise on removal is appreciated.. My options as I see are drilling it out or Removing the head and taking it to a machine shop, this I see as a last option. HD quoted $900+++

I have watched a couple of videos on how to repair, and I am trying to avoid removing the head. There might be enough threads to get a bolt in there and call it a day, I will try that first. On one video, the guy drilled a little then he hammered in a Torx socket in there and the SOB came out.

 

There is this kind of tool available - Jim's Machining Exhaust Stud Drill Plate 1705 | eBay

Once drilled it then just needs the threads cleaning out.

I have read other posts on screw extractors and the like but they have proved ineffective and made the situation worse.

 

Jim's flange jig and left threaded drill bits, may just come right out. I would not bolt it with minimal thread, it'll strip.

 

Before drilling or trying to remove the broken stud using the Jim's tool, soak it with Kroil penetrarting oil overnight. It's the best at penetrating rusted parts I've found.

Before trying to remove any rusted nut, I soak the nut and stud before trying to remove the nut. If the nut does not turn any when trying to remove it in the normal direction, I give it a just little effort tightening it and then try to remove it again. And if you feel it starting to get tight when removing, stop and put more penetrating oil on the threrads and tighten it up a little before continung to remove the nut.

Hope the removel goes well. Take your time and go slow.

Paul