Exhaust Stud Help

CALfeRacer

CALfeRacer

Fat man on a little bike
So, I managed to punch a hole in my head by attempting to drill out the broken stud. Genius, I know. Anyways, I have come up with three different ideas for how to plug the hole and still have an exhaust stud holding my pipes on. The picture below should be pretty self explanatory, but please feel free to ask questions and give feedback. I want to get a consensus for what the best way to proceed is. Thanks!
ExhaustStudOptions_zpsc8edf93e.jpg
 
hillsy said:
Helicoil or Threadsert.
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One of the shop techs was babbling on about a helicoil last time I was in the shop. Mind explaining it to me, since he didn't really? Ideally I would be able to have a stud and cap nut (like the original design..) so that I can remove the exhaust when necessary. This would be nice seeing as once everything is all set mechanically I would like to clean up the pipes and possibly fab up a new exhaust.
 
Nvm, I looked it up! Should I then put a helicoil in so that I can plug it with a 6mm (stock) as opposed to the 8mm? I guess that still leaves the problem of not being able to remove the stud, since the hole goes through to the cam area.
 
hillsy said:
Helicoil the hole then Loctite the stud in.
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Alright. Do they have helicoil sets at say a home depot or a local autozone? I'd like to get this done tomorrow so I can get out riding again ASAP :D
 
Alright, I guess I'll check out the helicoil. I might just buy a slightly oversize M6 bolt and cut the head off to make my stud, then use a cap nut so I can take the pipe on and off. I don't really have any desire to pay for a Honda spec stud when I could just make my own with a bolt and a grinder. Will the torque of trying to take the cap nut off in the future rip the stud out? I noticed that on the other stud on the pipe comes out with the cap nut. Maybe JB weld the back of the stud in to place?
 
Use a high strength Loctite. There's different types for different applications. JB Weld is not as good.


And yes - Loctite the Helicoil and then the stud. You should be able to get an M6 stud at Autozone or any other car parts shop. My local hardware shop even has them.


Then use anti-seize on the exhaust nuts.
 
hillsy said:
Use a high strength Loctite. There's different types for different applications. JB Weld is not as good.


And yes - Loctite the Helicoil and then the stud. You should be able to get an M6 stud at Autozone or any other car parts shop. My local hardware shop even has them.


Then use anti-seize on the exhaust nuts.
Click to expand...
That high strength stuff available at autozone as well? By Loctite the helicoil, do you mean put Loctite on the side of it then put it in, plus Loctite the stud before screwing it in to the Helicoil?
I have M6, 7, and 8 bolts as of right now from the local home depot. I know they don't have any metric studs. I'll check autozone to see what they have. Worst case, I'll just chop the head off of one of my M6 bolts.
Sorry to be asking so many questions, I just want to make sure I get this done right! Don't want oil shooting out of my head or my exhaust falling off.. :P
 
You really want a stud in your case because you don't have an "end" to the hole your stud is going into. A stud will seat itself at the start of the helicoil when the threads run out and you can torque it down a bit. You won't be able to do that with a straight threaded bolt.
 
If you can't find a new stud take one out of the other ports to use in the helicoiled thread - then use your cut down bolt in the "good" thread.
 
Well, I guess the question of what to do has been answered. I bought the helicoil and went to work. I looked inside the cam area to see where the hole cam through and... well I didn't find anything. I looked again at the hole, and saw it had a back. I must have nicked an internal oil passage or something. So I put the helicoil in and I'm just going to use a bolt, seeing as I don't have to block off the back of the hole off. Thanks for the help!
 
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