S1 Publishing(Oxford)© 1999-06

World of motorcycleS
S1 Publishing(Oxford)© 1999-06
 Stud Extraction.
 When working on older motorcycles, especially road machines, studs, screws and bolts can find themselves rust welded into the machine, I mean almost impossible to remove.
 Here are some ways on how I dealt with the problems I had on one of my machines.
 I snapped the exhaust stud while trying to remove the exhausts, this happens quite often so I was not surprised. There was no thread left to put on a nut on it.
 The wheel type of stud extractor was too large to fit, I was able to get the socket type to fit, I had left the stud with plenty penetrating oil on it, and still no luck.
 I then tried heating the stud with a blowtorch no get it as hot as I could, this sometimes breaks the rust and helps with removal. 
 Still I had no luck, in fact the stud sheared again, and now was too short to fit the socket type extractor onto.
 There were only two options left, one being grind until flat, drill a new hole and re-tap the thread, the other was to get a nut welded onto the remaining part of the stud.

The wheel type, usually does the job, IF you can get room to use it.

The socket type, comes in a range of sizes expensive, but well worth buying if you do lots of mechanics.
 We found a nut just small enough to be hammered onto the stud, until about 5 mm stuck above the nut, then we welded the nut onto the stud, while the weld and stud were cherry red, we hammered the socket onto the nut, this has to be done whilst the weld is still cherry red, or otherwise the weld drip's over the side of the nut, stopping the socket fitting.
 We then took the crack bar and tried to remove the stud.  It worked on the three studs which this happened to.

stud, nut, weld all off, and the inside thread intact