Exhaust headers

[SDN]

After Bike safe, was inspired to begin work on installing Kayla's new headers. My god the old headers might as well be welded on! in the end got very violent with a large crowbar and lump hammer / chisel. The evil headers yielded, but I have broken two exhaust studs which I will now have to drill out - b***ocks.

When I have the fitted, Will have a mess with jetting etc and post a report

lot of skin missing on knuckles etc.

[Mincehead]

Oh yes, Yamahahahahaha`s stupid alloy collar design over steel studs, MUPPETS!

[SDN]

Did battle with the broken exhaust studs today - what bar stewards! The metal had gone unbelievable hard drills kept skating of the stud and going blunt + obviously the drill would much rather bite into nice soft alloy then F hard steel. I have ended up with oversize holes holes tapped out 10mm. Am buying some uneven studs 10 / 8mm stainless from a volkswagon spares dealer - apparently a common fix on VW air cooled boxers, which I will screw in with loads of locktite. To be finished off with brass exhaust nuts. Christ this engine mod agro better be worth it.!

[Mincehead]

Ahh well you should have centre punched them after grinding their faces flat, then using a centre drill, much more rigid, no flex:

http://www.drill-service.co.uk/Product. ... 00&Tool=10

I have a range of carbide centre drills, super sharp, no wandering and a really good centre are a must for drilling studs.
I also have some left hand drills, brilliant for drilling virtually all the way up to tapping diameter (in this 8 x 1.25 case 6.5mm is the closest I have) and more often than not they`ll wind out what`s left of the broken stud too.

http://www.phantomdrills.co.uk/ShowProd ... ?CatID=516

My years in engineering meant I could order such goodies at heavily discounted prices.