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Buell Motorcycle Forum » Quick Board Archives » Archive through March 31, 2008 » I see a lot a post for broken exhust studs, everyone should do this. « Previous Next »

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Paw
Posted on Saturday, March 29, 2008 - 12:19 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Drill out the current broken stud to the next size drill tap. A Q drill for a 3/8 24 stud. When i had 2 of the 5/16 studs break on my bike just from vibration i went to the 3/8 24 and have not had a stud break since. There is plenty of material to drill out to the next size. What i used for a stud. I went down to my local ACE hardware and bought a regular 3/8 24 X 1 1/4 stainless bolt with a washer and locking nut to match. Just make sure you do not drill to deep, drill about a 5/8 inch deep and straight as possible and have the tap straight and square when tapping. Use a bottoming tap. I was able to do this all with a hand drill, T handle tap wrench and some tap ease lubricant. The easy way the get the stud all the way in the hole and make sure it's nice and snug. Take two nuts and lock them together on the stud. Then simply turn the stud in and tighten it up a little. When you have all that done do not for get to open the hole on the flange this is where the material is thin on the outer edge but it still works great just use a 25/64 drill.
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