Well my new pipes showed up over the weekend so I decided to run out to the shop and pull the old ones off. The first three header nuts came off no problem. The last one (the one on the front head behind the frame tube) felt a little tight and before my brain could stop my hand I snapped the stupid thing off flush. I'm pretty sure unless my local shop has some special tool or method of drilling those out with the head still on the bike I'm gonna have to pull the head. What a bone head mistake. I've never torn down a harley motor and I'm thinking I'll just load the whole thing up and take it to my indy and let him mess with it. Anyone ever had this done? It's a shame I don't have the coin for a big bore kit... be a good time to just tear the whole thing down.

 

your indy should have no problem getting it out.

 

Thet will have to pull the head but they will get it out.

 

It probably won't cost as much as you think.

 

I hope not. I have a tendency to assume the worst when stuff like this happens. I gave a call to the shop earlier and left a message. Hope to hear back today or tomorrow.

 

Id just pull the head off and take it to a shop....not hard to do...itll save you some coin

 

broken flush is easier to drill out.
You can do it yourself. Just center punch the middle and drill it making sure no to go too deep. Steady hand with a small drill should do it.
Drill size should be one size less the actuall tap drill size. and just run a tap in it with some good tapping oil and air hose to get the chips out.
Just don't go too deep.
Get a new studd first and you will see how much thread and what size you need.

 

There's lots of good info on this forum on how to remove that stud. I like PKellyMC's idea on posts 10 and 15 of this thread. Do a search on exhaust stud and you'll find lots of good stuff. If you decide to do it yourself and try using and EZ-OUT, just make sure to use the largest one you can, take it slow and easy and use lots of penetrating lube (not WD-40).

Good Luck!

 

If you decide to do it yourself on the bike, be sure to close off that exhaust port so nothing can get in there while drilling and cleaning.