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Thumper74
Posted on Friday, June 07, 2019 - 03:53 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I found two broken studs on my 2000 S3T this morning and will be trying to get the pipe off tonight to see how far down the studs are broken.

Does anyone have the stud jig to drill it out I could barrow if I pay shipping and put down a deposit?

Thanks!
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Xbpete
Posted on Friday, June 07, 2019 - 04:45 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I have a Jim's Tool that I would be glad to lend you...

Send me an email, no charge... can mail it from NY in the AM

2xbpete at gmail .com
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Mnscrounger
Posted on Friday, June 07, 2019 - 04:53 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

IF you can, try to find a left hand drill for the jig. Sometimes you get lucky, and between relieving the interior of the stud, the heat of the cutting, and the chip curling up the drill flute, it sometimes can catch and unscrew the stud remnant right out. (note: sometimes should be emphasized)
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Thumper74
Posted on Friday, June 07, 2019 - 07:05 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Thanks guys. I'm thinking that if the rear stud won't come out without a fight, I'm going to have to pull the rear head for access.

Mnscrounger, I've got a set of left handled drill bits for this reason and have had great luck getting them to back out.
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Slaughter
Posted on Friday, June 07, 2019 - 07:56 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I'd plan on following with heli-coil or keensert or similar. Once you have the hole, drilling and tapping for the hardened threaded insert is easy. You can then get roller-forged studs.
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Buellish
Posted on Friday, June 07, 2019 - 09:11 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

James,do you have new studs yet?
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Thumper74
Posted on Friday, June 07, 2019 - 09:44 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Xbpete, I'm sending you a message now.

Buellish, I do not have new studs. I was considering new HD ones or I believe I found some arp ones. Why?
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Buellish
Posted on Friday, June 07, 2019 - 10:00 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I have three new HD studs that I will be happy to donate to the cause if you want them.I bought 4 when I only needed 1 and don't have anything that uses them anymore.
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Thumper74
Posted on Saturday, June 08, 2019 - 03:29 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

That's awesome, I'd happily give them a new home on the bike!
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Xbpete
Posted on Saturday, June 08, 2019 - 09:48 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Tool is on the way Thumper..
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Buellish
Posted on Saturday, June 08, 2019 - 10:00 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I replied to your PM,if you don't get it email me at the address at the bottom of my profile page.
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Tootal
Posted on Saturday, June 08, 2019 - 12:19 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

With the tool you should be able to get the stud out clean. However if something goes wrong and the threads are damaged don't use a heli-coil, a timesert or other solid threaded bushing is much better. My experience with heli-coils is they are great to get you home but ultimately fail with time.
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Thumper74
Posted on Saturday, June 08, 2019 - 02:10 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Tootal, they are clean breaks and I've got a 90 degree drill with some left hand drill bits, so I'm hoping they walk their way out.

If I have to pull the heads, which isn't necessarily a bad thing, I may just send them to NRHS for their Stage 1 port and a 1250 kit. It wasn't really in the budget, but desperate times and all that.

See you in August?
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Zac4mac
Posted on Sunday, June 09, 2019 - 04:00 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

If you ,might be sending me the heads, I can do the stud repair.
I have the Jim's tool and have a very good record of saving the threads.

Much rather remove a stud with a drill than an easy-out or tap that requires diamond and more patience...

Z
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Thumper74
Posted on Tuesday, June 11, 2019 - 12:58 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Zac, I'm hoping I don't need to send it to you. Then you'd have to port them and send me a 1250 kit with matching cams... and that's just not in my budget at the moment...
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Ourdee
Posted on Tuesday, June 11, 2019 - 04:08 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

1250 kit? Could you budget for it by mowing the neighbors yards? Where there is a will there is a way. I need to get a second buell to do dream mods on.
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Thumper74
Posted on Tuesday, June 11, 2019 - 11:25 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Ourdee, there's no free time for that right now. I've got four kids (1, 4, 11, 13), school full time and 50-60 hours a week at work. The 1250 kit would need ported heads, cams and supporting mods, which can come over the winter time. I just want to keep it on the road to ride for the time being.
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Ourdee
Posted on Wednesday, June 12, 2019 - 02:32 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I get it. (1, 4, 11, 13), You are a blessed man.
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Thumper74
Posted on Friday, June 14, 2019 - 10:34 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Well. Shit.

Left hand drill bit drilled really well, but ultimately didn't back it out.

Ez outs did nothing.

I did both putting a torch to it with no luck.

It looks like I'm going to need to pull the heads.
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86129squids
Posted on Saturday, June 15, 2019 - 12:57 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)



Sorry, man.
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Ratbuell
Posted on Saturday, June 15, 2019 - 01:02 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I've had luck with:

1. use the header collar as a "jig"
2. drill a small hole down-center of the broken stud
3. gradually increase the drill size
4. as you increase, try EZ-outs to see if you can remove the broken stud (steel) from the head (aluminum).
5. If not, keep track of where stud ends and head begins...and once your drill bit gets big enough, change to a tap, to simply put threads where they belong.
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Tootal
Posted on Saturday, June 15, 2019 - 09:40 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I feel your pain. I had to set one up in a milling machine. Both studs broke. Ended up with a 1/4" carbide two fluted end mill to take them out. Then a pick to start the first thread and luckily they came out like a spring! They can be a PITA! Once that aluminum oxidizes it expands and grips like hell! All I can say is once they're out, put the new ones in with anti-seize!
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Ourdee
Posted on Saturday, June 15, 2019 - 01:05 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

It took me forever to learn not to run a standard tap back through aluminum to clean up threads.
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Tootal
Posted on Saturday, June 15, 2019 - 02:46 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

That's true. They make thread cleaners that look like a screw with some grooves cut in it lengthwise. You can make one with a good grade 8 screw and a cut off wheel. Running a tap into aluminum will take out more aluminum and make the thread weaker.
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Thumper74
Posted on Monday, July 15, 2019 - 01:21 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I gave up and dropped the heads off at a machine shop. They had to to thread inserts to fix it.

I just picked the heads up this morning and I'm just waiting on a gasket kit!
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