Another newb question - broke off muffler to cylinder stud...

Another new (1982) Honda Express project (3rd on this summer). 6mm nuts holding muffler pipe to cylinder really rusted, was able to get one off with a lot of penetrating oil and slowly loosening, tightening, (chasing threads). Second one snapped off. I did not take off muffler yet, so don't know how much I'm left with to "grab" on to.

I see from parts diagrams that it's a 6mm stud and still available - so whats the best way to proceed? Heat and vice grips and hope it breaks loose? Drill and easy-out or drill out and retap? Or???

Thoughts appreciated.

Thanks in advance,

Joe

Re: Another newb question - broke off muffler to cylinder stud...

All the above .

Why haven't you done them already ?

Re: Another newb question - broke off muffler to cylinder stud...

just waiting to see if there was a better idea from all you experts. I'm kind of new to the mechanic game and always willing to learn. (plus, waited so the grandson could still ride it before I broke it some more).

Joe

Re: Another newb question - broke off muffler to cylinder stud...

Ride ? With an ill attached exhaust ?

That's just buying a lot more 'broke' .

Best get it fixed before any more riding .

Re: Another newb question - broke off muffler to cylinder stud...

Worst case scenario you buy an m7 tap and tap it to m7. Ace hardware has m6 and m7 automotive studs for like $.40.

Re: Another newb question - broke off muffler to cylinder stud...

It's not really ill attached. More like rusted on. But, having said that, it'll be worked on pronto. Was just trying to get some ideas on which way to go about fixing it.

Thanks,

Joe

Re: Another newb question - broke off muffler to cylinder stud...

Oh, good plan. I was going to order a stud from local Honda dealer, but this sounds cheaper and more convenient.

Thanks,

Joe

Re: Another newb question - broke off muffler to cylinder stud...

> Joe Rich Wrote:

> -------------------------------------------------------

> Oh, good plan. I was going to order a stud from local Honda dealer, but

> this sounds cheaper and more convenient.

>

> Thanks,

>

> Joe

A decent hardware is much more handy and generally cheaper than a dealer .

Been a very long time since I've bought from a dealer .

With just a little imagination , you should be able to make anything work . ;)

Re: Another newb question - broke off muffler to cylinder stud...

Allen bolts. The answer is always Allen bolts, I take the studs out of all my bikes. With the exception of the cylinder studs of course.

Just run down to fastenal and pick up some m6 allen's in the approx length and some washers.

Re: Another newb question - broke off muffler to cylinder stud...

> Aaron Blair Wrote:

> -------------------------------------------------------

> Allen bolts. The answer is always Allen bolts, I take the studs out of

> all my bikes. With the exception of the cylinder studs of course.

>

> Just run down to fastenal and pick up some m6 allen's in the approx

> length and some washers.

I just snapped Allen bolts on a kitted Batavus I have. Put the Allens in and a month later went to take the exhaust off and both snapped

Re: Another newb question - broke off muffler to cylinder stud...

Never have I ever snapped an Allen bolt. I never install the intake or exhaust studs and just run Allen bolts. You do have to be careful installing them so you do not strip out the holes by misthreading them. Which I have also never done. Just be careful and I find that they are much easier to work with than the studs.

Re: Another newb question - broke off muffler to cylinder stud...

> Jay Rivett Wrote:

> -------------------------------------------------------

> Never have I ever snapped an Allen bolt. I never install the intake or

> exhaust studs and just run Allen bolts. You do have to be careful

> installing them so you do not strip out the holes by misthreading them.

> Which I have also never done. Just be careful and I find that they are

> much easier to work with than the studs.

These were m5 allens cause this was an m1 kit. I thought about tapping to m6 but was too lazy. Now I've got my work cut out for me

Re: Another newb question - broke off muffler to cylinder stud...

Update:

Was unable to get a vice-grip on the left-over nub. Instead of grinding it off, decided to take the cylinder head off and bring to one of my Eagle Scouts who now has a metal fabrication business. Welded a nut (3 times) onto the nub and was able to back out the broken off stud. Waiting for new gasket and stud. Should have them tomorrow to put cylinder back on. Then it's burn out the muffler when the rain stops.

Thanks all for the ideas and support.

Cheers,

Joe

Re: Another newb question - broke off muffler to cylinder stud...

> Joe Rich Wrote:

> -------------------------------------------------------

> Then it's burn out the muffler when the rain stops.

Why wait for that barbarism ?

Just fill it with oven cleaner , wait and rinse . Maybe repeat , if needed . ;)

Re: Another newb question - broke off muffler to cylinder stud...

I like bonfires. Plus fun to watch the flames shooting out.

Joe

Re: Another newb question - broke off muffler to cylinder stud...

> Joe Rich Wrote:

> -------------------------------------------------------

> I like bonfires. Plus fun to watch the flames shooting out.

>

> Joe

I like bonfires , too , but I don't burn trash in my fire pit . ;)

Re: Another newb question - broke off muffler to cylinder stud...

Now who says an unmolested 1982 Honda Express muffler is trash? I couldn't believe it wasn't cut open or drilled out or tinkered with in any way.

Joe

Re: Another newb question - broke off muffler to cylinder stud...

I didn't mean to insinuate that a Honda exhaust was trash .

What might be inside that exhaust would be ... :)

Re: Another newb question - broke off muffler to cylinder stud...

Peace - I certainly wouldn't roast any weenies or marshmallows over the muffler while I'm cooking it.

I was surprised though to find it intact!

Joe

Re: Another newb question - broke off muffler to cylinder stud...

Do some brats over the open flames to get a little char while getting the fire hot enough and big enough . Then sit back and enjoy a good eat while watching flames shoot . ;)

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