Bugger

Fitting my new exhaust system tonight. Should have been an hour long job. But every exhaust attachment bolt is severely corroded. Gave them all a good soak with penetrating oil last night but disaster has just struck. The front cylinder exhaust stud has just sheared off. I gave it a small turn with a socket, felt it give a little then it just sheared off. Picture shows what is left sticking out of the barrel. Other side came lose but unscrewed the stud - not the nut off the stud.

Not sure if there is enough to get some mole grips onto the stud to have a go myself or whether this is a dealer job. I really don't want to get into drilling out this stud in sutu. Does anyone have any experience of this? Any tips or advice before I dive in?

Also I see that there is a washer/spacer on the sheared off stud. This is only on this side - the other stud did not have this spacer. Is this normal?

Oh m8 that is shite My only suggestion is to get a anti clockwise drill bit if you can, as that might shift it on it's own. If not drill it out a fair bit and hopefully you can use an easy out to prise it out. I would be very tempted to use some heat on it as well, do you have a blow torch? Personally I always get the headers hot from the engine running before I attack the nuts as they seem to come out much easier then.
Hope you sort it m8.

Edit: looking at your pics you still have the header there so I'd use the engine as it will heat the bolt from the inside and won't damage the powder coat.

For all of you snapped-off stud fans out there here is where I got to tonight.

Got the seized on spacer off pretty easy and then tried the molegrip route but no luck. It was worth a try but I just couldn't get it on with enough grip to not turn slightly and it was obvious that if I carried on I'd just munch through the stud.

So, before the remaining thread was buggered I screwed on a spare nut and got my old stick welder out. But I'm a pretty shitty welder and I've got the bike inside to work on it. There was a smell of burning and I looked down past my welding mask to see that the splatter was burning holes all over the hardwood flooring we've got in the house! Good job Amy is away in Spain, she'd have killed me!

So I stopped for the night to reconsider. I think I'll wheel the bike up the road to a garage and get them to really weld it on properly. I reckon I've only got one go at this and to get a socket on and have the weld keep snapping might ruin my chances.

Fingers crossed for you mate.

good stuff!
i'm glad it came out, drilling it would have not been much fun...

now off i go to clean and grease mine, before they get to the same shape

Ha ! you a funny one Bic, Kudos to you my man for your choice, I figure your bound to be blessed, intelligent and good looking, otherwise your bike would not be a SD, and your arm candy wouldn't look so stunning.

Nice photoshop

Hey smoky, I know you know the ins and outs, joe would use a wire brush for a while on that type of rusty fastener if and when I see the stuff. then some fantastic PB nutbuster, (smells like moth balls).

Joe, I am indeed a lucky guy to have my Amy. She is the best woman in the world and lets me have my bike in the house and tolerates my other love, (the SD). We have just found out that we are having another baby! I am very happy (but not good looking) Just lucky:lol: