Seized exhaust nut removal

[joebloggs]

My exhaust is blowing somewhere near the top of the headers, a common issue from what I've read on here, also the nuts and studs have become one. My question is has anyone tried welding another nut/bar etc to get some real heat into the area and if so was it successful?

[Bretty]

I put off removing my exhaust headers for ages, after previously snapping off 2 studs (and an e-z out) and having to do a full top-end rebuild.

This time around, I was lucky enough to get all the nuts off no problem with a little help from plusgas penetrating fluid and they now have a liberal coating of copper grease!

If they were really bad I would have seriously considered using a nut splitter to get the old nuts off and fitting new ones rather then applying any torque to the corroded studs.

I was reluctant to heat the studs on my bike, as although this seems like the easiest solution and seems to work for everyone, in my mind heating the studs will just accelerate how quickly they corrode in the future. Unless you are considering replacing the studs, which is another headache altogether.

Just my opinion,

Brett

[joebloggs]

The nuts and studs don't look so bad, paranoia is probably my greatest issue, although paranoid or not they can still sheer. Have been coating them in penetrating fluid for a week, maybe give them another week and I'll have a go at undoing them.
Shame the owners from new didn't spend a couple of mins each year removing and greasing them
Thanks for advice

[His Dudeness]

I've been through the snapped stud saga too. If I had to do it again I'd cut the nuts with a dremel before attempting to turn them

[Jules-C]

I managed to get about 5 of mine off after months of soaking with about every penetrating/release oil I could lay my hands on.  Managed to dremel another 2 off without too many problems and only small slices taken off the threads on the studs. These were done one at a time to allow plenty of time to stop me rushing.  Once the nuts were off they were replaced with stainless dome nuts. The last nut was impossible to get to with any control at the correct angles so I ended up cutting the exhaust off with the dremel as close to the clamp as I could and then dremelled the nut off.

Heating is worth a try if you have access to the kit.

The cost of stainless studs and nuts would put the price of a new bike up by about £5 I'd be prepared to pay the extra fiver

[Pickle]

I have just been through the snapped stud nightmare and that was only the one. My problem was access to drill out and helicoil because the frame was in the way, at one point I thought the engine might have to come out. It was a complete pain in the chuff and in hindsight I should have used a nut splitter or dremmel and taken my time. Over 3 weeks off the road at the height of the summer.

[joebloggs]

Just gave it another soaking with wd, booked in tomorrow afternoon at local garage, he says we can try to crack them open first if not he's going in with the welder. if that fails, or more to the point, if they sheer I'll drop the motor and take it back for helicoil. Bike's not on the road yet so not overly concerned about the time frame, would like to get it on the road this side of xmas though lol
Thanks for the replies and I'll let you know how I get on tomorrow

[Buzz]

I've been through the snapped stud saga too. If I had to do it again I'd cut the nuts with a dremel before attempting to turn them

Exactly what I did with mine together with a small cold chisel and dremel flexi-shaft.  Once the rad was off it took about 4 hours to remove all 8 nuts and fit the Motads with copper slipped brass domed nuts.  Didn't even need any penetrating fluid.

[Jules-C]

I tried a nut splitter but access problems mean it's not much use

[fazersharp]

Everything you will ever need to know (and some you dont need to ) you will find here http://foc-u.co.uk/index.php/topic,16432.0.html

[anutz]

yeah be careful....as the poor g*t who started the thread fazer# mentions, it can go very wrong, but i was a little bit of a novice aka idiot....i did on the flip side learn how to tear a bike to bits and eventually ( 5 months later ) have it back ship shape with some nice upgrades...


:lol

[joebloggs]

After much consideration I think I'm going to cut the pipes and drop the motor out. Hopefully will be able to split the nuts then and put the money I could have spent on helicoiling on stainless headers.