busted exhaust stud

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Oct 20, 2013 | 09:17 PM

avnsteve

Thread Starter

Intermediate

Joined: Jan 2007

Posts: 31

Likes: 0

From: Texas

busted exhaust stud

I busted the studs in the rear cylinder head of my friends 02 FLHR (road king). I've managed to extract one bolt yet broke off a drill bit in the other. I'm at the point where I'm tempted to just replace the head. Can anyone give me some guidance here, I've NEVER had success with E-Z outs and extractors, this is a good example. Ultimately, I'd like to know the part # of that head so I can just buy a replacement as I doubt the head will EVER hold exhaust any longer as the holes are over sized and off center. help?!

Oct 20, 2013 | 09:23 PM

prosnowsk8er

Cruiser

Joined: Sep 2012

Posts: 225

Likes: 5

From: calgary

Check out 340070 on this page, this guy makes great quality tools! Might be a cheaper solution.

http://www.georges-garage.com/tc_engine_2.htm

Oct 20, 2013 | 09:30 PM

BC45

Cruiser

Joined: Oct 2009

Posts: 195

Likes: 4

From: Washington

I would pull the head and take it to a machine shop. If the hole is not to oversized or off center they can drill it to the proper size to install a thread inset. It would also make it easier to remove the broken drill bit (not the easiest task).

Oct 20, 2013 | 09:37 PM

scoobs

Tourer

Joined: Jun 2007

Posts: 436

Likes: 0

From: Wisconsin

If the drill bit is still in there your best bet is to take off the head and find a machine shop that can do edm. At the very least with the head off you have it where you can get the angle on it.

Oct 20, 2013 | 09:49 PM

rmc115

Road Master

Joined: Oct 2006

Posts: 1,122

Likes: 23

From: Mishawaka,Indiana

i have a pair of new take off heads from a 03. pm me if you are interested. Mike

Oct 21, 2013 | 06:23 AM

skratch

Seasoned HDF Member

Joined: Jan 2007

Posts: 20,616

Likes: 4,440

From: anacoco, la

Quote:

Originally Posted by prosnowsk8er

Check out 340070 on this page, this guy makes great quality tools! Might be a cheaper solution.

http://www.georges-garage.com/tc_engine_2.htm

this is what you needed before you started drilling crooked and breaking off eazy outs in the bolt. this tool is awesome. I had an exhaust stud broken off and the indy used this. the drill is so close to size that after it is drilled out, you just reach in with a pair of pliers and pull the thread from the bolt that is remaining. makes life much easier.

Oct 21, 2013 | 07:04 AM

Gunnysgt

Grand HDF Member

Joined: Oct 2009

Posts: 3,824

Likes: 603

From: Myrtle Beach SC

Broke one off on my Panhead, replaced it with a Helicoil. Worked great

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Oct 21, 2013 | 08:18 AM

slider1156

Tourer

Joined: Jan 2011

Posts: 401

Likes: 8

Georges tool is the ****. Left handed drill bits are good also. If you pull the head you better pull the jug and replace the lower jugg gasket or it will leak.