I am trying to remove the plug so I can install the better sensors. With that said, my first attempt was to use a hex head socket - stripped out the socket inset. Attempt #2 - I drilled a hole in the center and tried to use an easy out - no luck. I also tried heating around the bolt but it isn't budging. I'm afraid to try and drill around the threads for fear of damaging the pipe threads. Any other ideas? I don't want to have to buy a new headpipe but it isn't looking good at this point.

Thanks ahead

 

At this point I would drill it over and over again until it is thin enough to collapse on itself to get it out without messing up the threads...

 

Unless you can get vise grips to hold on what is left sticking out, keep drilling.

 

Heat it with a torch until the outer bung gets red then use the easy out

 

Looking at the pics I can not tell what all that **** is around the plug. Was it welded in?

If not, I would take a good wire brush to the threads around the plug, clean out all that crap, then hit it a few times with PB B’laster
(waiting for it to soak in between each application, tapping it for a few minutes before re-applying) then let it sit overnight.

Then try a good ez-out on it.
.

 

If it were mine I'd drown it in wd40 overnight then cut a groove in the top with a hacksaw, then take a hammer and chisel and start belting the christ out of it!!

'06 NT, 95", S&S .510g, V&H BR 2-2, K&N AC, P&P Heads, SEPST.

 

I will guess that is some grease around the threads and that it is NOT welded to pipe.
I will guess that the threaded insert had some RED threadlocker applied.
Another guess is that pipe is off the bike.
Consider cleaning the threaded part really well.
Applying a torch to the threaded part only and getting it as hot as possible to break any bond.
Walk away.
Let it cool for about 15 minutes and hit it with the heat again.
Walk away and come back in an hour or after a meal.
Then, get some automatic transmission fluid and pour it inside the hole, plug hole with wax, chewing gum or whatever you have and seal threaded hole from leaking and flip pipe so the ATF puddles in that raised tube area.
Walk away for an hour or two.
Then return and try to remove the plug again.
The high heat breaks bonds and the ATF seeps into the threads to release holding power.
When done make sure to get some pharmacy store alcohol and clean pipe well inside and out because the ATF will fill your garage with smoke if not removed when motor is started.

 

Thanks for all the ideas. I ended up welding a big-*** nut to the pipe plug and got medieval on it with a half inch breaker bar - came right out. After it was out we noticed it appeared to have been threaded in about an 1/8". Damnedest thing me and my brother-in law had ever seen.

Thanks again

Bill

 

Weld a nut to it, heat the pipe and remove it. Have a tap ready to clean up the threads.

LOL I read your last post after I said weld a nut to it - good deal it's out!