So my nightmare came true. One of my header screws snapped off.

[BeerIsSoAwesome]

I was removing the exhaust to install fresh header gaskets and hopefully cure what I *believed* to be an exhaust leak. 3 of them came out nicely, and the last one was sticking, but coming out bit by bit. No it wasn't. It was twisting off. 

This screw is REALLY in there. I was planning on doing the stud mod, and already ordered a pack of full-threaded 50mm M8 bolts in 12.9 high tensile steel. I wish I had just given up when the stud snapped off, but I went at it with PB Blaster, and a hammer, and vise-grips and made a bit of a mess.

I really don't want to drill it, and I don't know anyone who does heli-coils, and this thing sounds like an expensive nightmare. 

I do, however, know a metal sculptor who is very good with a TIG welder and I'm thinking of asking him to simply extend the stuck bolt fragment with a solidly-welded piece of threaded stud. I'd just tighten the other 3 new bolts in with Loctite, cut the heads off and call it a day. I can always hit it with a spritz of high-temp paint for corrosion resistance. What do you guys think?

[Snake2715]

Its not your night is it?

Any of it sticking out past the flange when the flange is on?

[yamahonkawazuki]

I was removing the exhaust to install fresh header gaskets and hopefully cure what I *believed* to be an exhaust leak. 3 of them came out nicely, and the last one was sticking, but coming out bit by bit. No it wasn't. It was twisting off. 

This screw is REALLY in there. I was planning on doing the stud mod, and already ordered a pack of full-threaded 50mm M8 bolts in 12.9 high tensile steel. I wish I had just given up when the stud snapped off, but I went at it with PB Blaster, and a hammer, and vise-grips and made a bit of a mess.

I really don't want to drill it, and I don't know anyone who does heli-coils, and this thing sounds like an expensive nightmare. 

I do, however, know a metal sculptor who is very good with a TIG welder and I'm thinking of asking him to simply extend the stuck bolt fragment with a solidly-welded piece of threaded stud. I'd just tighten the other 3 new bolts in with Loctite, cut the heads off and call it a day. I can always hit it with a spritz of high-temp paint for corrosion resistance. What do you guys think?

how deep in is it? lmk ill guide you from this point on once i know more.

[BeerIsSoAwesome]

I was removing the exhaust to install fresh header gaskets and hopefully cure what I *believed* to be an exhaust leak. 3 of them came out nicely, and the last one was sticking, but coming out bit by bit. No it wasn't. It was twisting off. 

This screw is REALLY in there. I was planning on doing the stud mod, and already ordered a pack of full-threaded 50mm M8 bolts in 12.9 high tensile steel. I wish I had just given up when the stud snapped off, but I went at it with PB Blaster, and a hammer, and vise-grips and made a bit of a mess.

I really don't want to drill it, and I don't know anyone who does heli-coils, and this thing sounds like an expensive nightmare. 

I do, however, know a metal sculptor who is very good with a TIG welder and I'm thinking of asking him to simply extend the stuck bolt fragment with a solidly-welded piece of threaded stud. I'd just tighten the other 3 new bolts in with Loctite, cut the heads off and call it a day. I can always hit it with a spritz of high-temp paint for corrosion resistance. What do you guys think?

how deep in is it? lmk ill guide you from this point on once i know more.

I thought it was backing out, but I compared the length of the portion sticking out to the length of the portion in my hand, and I think it's in all the way. I doubt it budged at all, which is what's making me want to weld a stud onto it.

Its not your night is it?

Any of it sticking out past the flange when the flange is on?

Ha, the carb sync went terribly last night, and someone suggested I install fresh gaskets before even bothering with the carbs, so that's what I was doing when I broke the bolt off. No, it doesn't stick out past the flange. It protrudes probably 3/8" beyond the fins. There was more to work with, but I worked at it until I had mangled the remaining stud a bit.

[yamahonkawazuki]

MIGHT be able to get a 2 sided stud into it. with red locktite. time it works loose, engine would be long dead. unless your luck is like gsjack and you could get 100k on yours

[BeerIsSoAwesome]

MIGHT be able to get a 2 sided stud into it. with red locktite. time it works loose, engine would be long dead. unless your luck is like gsjack and you could get 100k on yours

Are you telling me to tap and thread it for a smaller stud, and use it to join two M8 studs? Is this a better option than just welding on an extension?