panic attack

sarc · 10-29-2009, 07:04 AM

trying to remove a muffler stud, it broke inside. drill the stud and tried to re-tread. the re-thread broke inside. used an extration tool and then the side of the hole let go. what can I do. can I clean this up, re weld, re drill and re tap? its a vulcan classic 1500. the break is on the rear muffler stud.

thanks

dogdoc · 10-29-2009, 08:17 AM

Boy what a panic situation. When you enlarge the pic you cant see what we need to see. Sounds like you might need professional help now, I would. :-)

**ringadingh** · 10-29-2009, 09:00 AM

Your going to have to get it welded up and then retap the hole.
Hupefully you can get it welded together without removing the cylinder if your lucky. Find a place that welds aluminium and see if they can weld the broken piece back on and then rethread the hole. If they can't they have to build it up the area with weld, then drill and tap. If that is a blind hole which I think it is, it may be difficult to do installed on the bike.

caper · 10-29-2009, 09:35 AM

Well I hope everything goes well for you !

cactusjack · 10-29-2009, 09:58 AM

Oh, crap! I hate it when that happens. The steel stud in the aluminum head probably caused a galling situation.

I wish I knew what to tell you to do. Maybe consult an automotive machine shop for advice?

**Top Cat** · 10-29-2009, 11:36 AM

I don't know much about the 1500 classic but the first thing I would do is see if there was any way to make a bracket to attach the muffler some place else. Seems that would be the easiest way out.

cactusjack · 10-29-2009, 12:11 PM

Quote:

Originally Posted by Top Cat (TC)

I don't know much about the 1500 classic but the first thing I would do is see if there was any way to make a bracket to attach the muffler some place else. Seems that would be the easiest way out.

Seeing as how this is where the exhaust pipe bolts to the head, that might not be possible. You need a good tight seal there.

**Top Cat** · 10-29-2009, 12:43 PM

OK, got it now, Thought it was just holding the muffler on some place.

cactusjack · 10-29-2009, 02:18 PM

Quote:

Originally Posted by Top Cat (TC)

OK, got it now, Thought it was just holding the muffler on some place.

Yeah the OP said muffler, but it's where the exhaust flange bolts up. Nasty place to have a boo-boo.

macmac · 10-29-2009, 07:50 PM

panic..... You need a great tig welder/machinist. The engine should be removed and the head taken off. The welding could be done in place, but not the drill re-thread. At least i couldn't and get it right.

The welder must be proficent in magnesium rods, as normal aluiminum isn't going to hold well.

This one is a real bummer, because not many welders get a chance to weld in this alloy, and the rods themselves are hard to come by. A helicopter welder machinst is best.

.................................................. ............ The rest of you guys really need to clean (wire brush these studs, then paint them by brush with hi temp paint from a rattle can you mist into the paint can cap, NOT painting exactly where the acorn nuts go, and antiseize that bit of threads.

These may remain with steel and chrome nuts if you like, or go my way with ss, polished bright, but still antiseized.

This is a difficult repair.

macmac · 10-29-2009, 07:53 PM

With the above said, days of some penatrating oil should have been applied, and any time you walked by the nut should have been tapped lightly to assist the flow of the oil.

Then heat in a torch would have prevented any of this. A guy with cutting torches could have removed this nut with a small welding tip, for cheap. He could make temp heat shielding too.

If anyone local to me gets a stuck on nut here, please stop by. I would rather do this for free than see the expence of this repair.

The other way out is a whole new head.

zoom45 · 10-29-2009, 09:23 PM

Probably too much pressure for JB weld. Does it have enough lip where you could cut the outer edge flat and use a J nut that would slip over the flange? If it has enough lip to hold the J nut it may get you by until you could fix it the right way.

http://www.boltproducts.com/images/t..._retainers.jpg

Zoom45

sarc · 10-29-2009, 09:40 PM

what is a jb weld?

zoom45 · 10-29-2009, 10:02 PM

A two part adhesive you mix together to repair metal. I have used it to fix transmission cases and blocks. It can be drilled and tapped too.
http://jbweld.net/index.php
Zoom

AlabamaNomadRider · 10-29-2009, 10:44 PM

I would try to find a local machine shop, a one man operation. And would hope the man has been doing this for 30 years or so. He should have some idea of how to solve your problem.

I certainly hope everything works out for you. Keep us posted with a new thread.

10-29-2009, 07:04 AM	#1
sarc Jr. Member Join Date: Mar 2008 Location: Courtenay, British Columbia, Canada Posts: 49	panic attack trying to remove a muffler stud, it broke inside. drill the stud and tried to re-tread. the re-thread broke inside. used an extration tool and then the side of the hole let go. what can I do. can I clean this up, re weld, re drill and re tap? its a vulcan classic 1500. the break is on the rear muffler stud. thanks Login or Register to Remove Ads
	0

10-29-2009, 08:17 AM	#2
dogdoc Top Contributor Join Date: Jul 2007 Posts: 5,263	panic attack Boy what a panic situation. When you enlarge the pic you cant see what we need to see. Sounds like you might need professional help now, I would. :-)
	0

10-29-2009, 09:00 AM	#3
ringadingh Join Date: Aug 2007 Location: Newmarket Ontario Canada Posts: 35,387	panic attack Your going to have to get it welded up and then retap the hole. Hupefully you can get it welded together without removing the cylinder if your lucky. Find a place that welds aluminium and see if they can weld the broken piece back on and then rethread the hole. If they can't they have to build it up the area with weld, then drill and tap. If that is a blind hole which I think it is, it may be difficult to do installed on the bike. __________________ 2002 Nomad aka Bountyhunter VBA #27 VROC #18951
	0

10-29-2009, 09:35 AM	#4
caper Sr. Member Join Date: Feb 2009 Location: Nova Scotia, Canada Posts: 1,137	panic attack Well I hope everything goes well for you ! __________________ Live in the NOW !
	0

10-29-2009, 09:58 AM	#5
cactusjack Mega-Contributor Join Date: Sep 2007 Location: Where it doesn't snow...ever! Posts: 21,926	panic attack Oh, crap! I hate it when that happens. The steel stud in the aluminum head probably caused a galling situation. I wish I knew what to tell you to do. Maybe consult an automotive machine shop for advice? __________________ Scott "Cactusjack" Hanks VBA #00105 H.O.G. #4250060 2011 H-D Ultra Limited 103ci :: 2011 HD Electra Glide Ultra Limited w/Stage 1 :: Rallies: Mesquite '08\|Custer '09\|Cortez '10\|Crescent City '11\|Kanab '12\|Antlers '12\|Estes Park '13\|Antlers '13\|Orofino '14\|The Dalles '17 Login or Register to Remove Ads
	0

10-29-2009, 11:36 AM	#6
Top Cat Join Date: Jul 2007 Location: Peoples Republic of New York State Posts: 15,154	panic attack I don't know much about the 1500 classic but the first thing I would do is see if there was any way to make a bracket to attach the muffler some place else. Seems that would be the easiest way out. __________________ Tim "TC" Conley VBA #9 2011 Victory Kingpin mine 2013 Victory Boardwalk -hers [LEFT][COLOR=#000000] [SIZE=4]
	0

10-29-2009, 12:43 PM	#8
Top Cat Join Date: Jul 2007 Location: Peoples Republic of New York State Posts: 15,154	panic attack OK, got it now, Thought it was just holding the muffler on some place. __________________ Tim "TC" Conley VBA #9 2011 Victory Kingpin mine 2013 Victory Boardwalk -hers [LEFT][COLOR=#000000] [SIZE=4]
	0

10-29-2009, 07:50 PM	#10
macmac Sr. Contributor Join Date: Apr 2008 Location: Tamworth New Hampster 06 1600 Posts: 12,484	panic attack panic..... You need a great tig welder/machinist. The engine should be removed and the head taken off. The welding could be done in place, but not the drill re-thread. At least i couldn't and get it right. The welder must be proficent in magnesium rods, as normal aluiminum isn't going to hold well. This one is a real bummer, because not many welders get a chance to weld in this alloy, and the rods themselves are hard to come by. A helicopter welder machinst is best. .................................................. ............ The rest of you guys really need to clean (wire brush these studs, then paint them by brush with hi temp paint from a rattle can you mist into the paint can cap, NOT painting exactly where the acorn nuts go, and antiseize that bit of threads. These may remain with steel and chrome nuts if you like, or go my way with ss, polished bright, but still antiseized. This is a difficult repair. __________________ 06 1600 Nomad Just call me Mac molon labe come and get it
	0

10-29-2009, 07:53 PM	#11
macmac Sr. Contributor Join Date: Apr 2008 Location: Tamworth New Hampster 06 1600 Posts: 12,484	panic attack With the above said, days of some penatrating oil should have been applied, and any time you walked by the nut should have been tapped lightly to assist the flow of the oil. Then heat in a torch would have prevented any of this. A guy with cutting torches could have removed this nut with a small welding tip, for cheap. He could make temp heat shielding too. If anyone local to me gets a stuck on nut here, please stop by. I would rather do this for free than see the expence of this repair. The other way out is a whole new head. __________________ 06 1600 Nomad Just call me Mac molon labe come and get it
	0

10-29-2009, 09:23 PM	#12
zoom45 Sr. Member Join Date: Jul 2007 Location: Terry, Mississippi Posts: 1,434	panic attack Probably too much pressure for JB weld. Does it have enough lip where you could cut the outer edge flat and use a J nut that would slip over the flange? If it has enough lip to hold the J nut it may get you by until you could fix it the right way. http://www.boltproducts.com/images/t..._retainers.jpg Zoom45 __________________ Bobby Risher Terry, MS Kawanow member # 124 South Central Group 2000 Nomad 1500 (carbed) 128,000 miles
	0

10-29-2009, 09:40 PM	#13
sarc Jr. Member Join Date: Mar 2008 Location: Courtenay, British Columbia, Canada Posts: 49	panic attack what is a jb weld?
	0

10-29-2009, 10:02 PM	#14
zoom45 Sr. Member Join Date: Jul 2007 Location: Terry, Mississippi Posts: 1,434	panic attack A two part adhesive you mix together to repair metal. I have used it to fix transmission cases and blocks. It can be drilled and tapped too. http://jbweld.net/index.php Zoom __________________ Bobby Risher Terry, MS Kawanow member # 124 South Central Group 2000 Nomad 1500 (carbed) 128,000 miles
	0

10-29-2009, 10:44 PM	#15
AlabamaNomadRider Sr. Contributor Join Date: Jul 2009 Location: Boaz, Alabama Posts: 13,742	panic attack I would try to find a local machine shop, a one man operation. And would hope the man has been doing this for 30 years or so. He should have some idea of how to solve your problem. I certainly hope everything works out for you. Keep us posted with a new thread. __________________ Gene Cross, Jr. Boaz, Alabama KawaNOW/VBA #1181
	0

Similar Threads
Thread	Thread Starter	Forum	Replies	Last Post
Terrorists Attack or not??	usranger74	Off-Topic	8	03-09-2011 09:19 PM
Panic attack - no more	sarc	1500 & 1600 Nomad	5	04-07-2010 10:32 AM
Oil change panic	tmskare	1500 & 1600 Nomad	17	03-19-2010 11:40 PM
In panic mode over Custom Lighting	rickyboy	Vulcan Nomad/Vaquero/Voyager	23	06-10-2009 06:59 AM
Attack Squirrel		Lighter Side/Jokes	1	10-13-2007 09:44 PM