Cafe racer project

[Tony a]

Cheers Goldy, yer it's more that I could of hoped for at this point, but taking it apart is really the easy part. Being able to put it back together will be the major test. I think the cost will be the major stopping point. I will only be able to get one or two parts done each month. But I took this on as a long term project so really not in a real hurry.

 

[Tony a]

Ok, it's been a bit of a stand still as I have had to buy some tools. Have had problems with taking the exhaust off, I snapped two bolts and so stopped to get an extraction tool. Also bought a number of other tools just in case I get any more problems. So tomorrow the engine and everything else will be removed and I can then start on rubbing the frame down. Watch this space.

 

[Tony a]

Help!!! I have two exhaust studs that have snapped off. I'm lucky as they have not snapped at the base so can get grips on them. My problem is I have tried to heat them and have sprayed them with wd40, but they will not budge. Does anyone have any more solutions to getting them out. Cheers in advance.

 

[japstar]

Help!!! I have two exhaust studs that have snapped off. I'm lucky as they have not snapped at the base so can get grips on them. My problem is I have tried to heat them and have sprayed them with wd40, but they will not budge. Does anyone have any more solutions to getting them out. Cheers in advance.

First, ignore all anti-cursing preaches of your mum and start cursing at your bike like a madman.
Helped me let off some steam and start over in a calmly fashion 8)

But in all seriousness:
You will most likely not be able to get them out. Aluminium has the tendency to corrode and jam those studs for good over time.
Go source a helicoil set (or v-coil or whatever brand)

Get some fresh drills that are sharp, and drill them out for starters.
Best is with a drilling stand, but it is managable with a hand drill too. Just start small (I usually start off with 2 mm).

Than drill and tap the thread for the helicoils and install them. Et voila, a new thread for you bolts that won't jam them as easily as the stock pure aluminium thread.

If I must start drilling out a few studs in a cylinder head, I replace all the threads with helicoil anyway. Could save you a lot of trouble in future engine work.

If a drill breaks of during drilling out the broken of studs:
Get a rotary tool to mill out the broken studs (yes you will screw up your head at first), get the hole you created welded, reshape the area where the stud must be and start drilling again.

 

[Tony a]

Cheers Japstar, will have to look into that. But to be honest I don't feel to confident drilling them out.

 

[japstar]

Cheers Japstar, will have to look into that. But to be honest I don't feel to confident drilling them out.

Nobody does the first time
You don't need a steady hand like a surgeon or whatever. But I do recommend no to drill them after a heavy night of drinking

Just be sure to center punch the broken studs before drilling.
I can also recommend not to use those heavy drills with a power chord. I prefer to use a wireless drill, as they tend to be less heavy and less powerfull. (the running out of battery during the job is a small nuisance with respect to broken drills)
Calmly drill, rectract very often to get the debris out, step up like 1.5 mm after eacht drilling step. And be carefull not to bend much bending stress on the drill.
And the biggest mistake everyone makes:

Don't get happy or enthousiast before drilling out the last stud! It's when you start feeling overconfident you start working too fast and screw things up.

And IF you screw up, find someone with a dremel tool and mill the stud out. Seems scary, with it's okay once you had to do it

 

[clem]

If you can find it in your area I would suggest Kroil. It comes in an orange spray can and works very well on aluminum. Used it on quite a few instruments that had sat out on the Gulf of Mexico since the 70's. Those bolts didn't stand a chance. Lol

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