It happens more often than not on older H-D models. The exhaust stud becomes frozen or seized in the head. We damaged the threads on our Road King while doing one of our Baggers Sound-Off videos. We tried the first go-to step in removing exhaust studs, the “jam-nut” method. You basically thread on two nuts, tighten them together, and then turn the back nut to remove the stud and jam-nuts as an assembly. This failed, the stud was too seized, and both nuts just unthreaded off together. So the next step was to weld on a nut and back the stud out that way. If this method fails all that is left is taking off the head and machining out the stud and re-tapping the hole for a new stud.
Cue our old pal Anthony of Chassis Design Co. We needed to head down his way to get some bars made for our Hot Bike Tour Baggers Build-Off bike, so we decided to kill two birds with one stone, as they say. Anthony was able to get the stud out by welding a nut onto it, but it wasn’t as easy as 1, 2, 3. Follow along as we get out that pesky exhaust stud.
Here is the old exhaust stud with the nut welded on the end. Not much stud left!
Starting off, Anthony sprayed the old stud with a heavy dose of WD-40 to give us a fighting chance.
After the WD-40 soaked for a few minutes it was wiped clear and Anthony welded on a nut to the end of the stud.
That puppy is smokin’ hot!
Once the stud and freshly-welded-on nut cooled, Anthony went in to try and unthread the assembly. The stud broke off rather than unthread a total of three times before it finally gave way and came out. Anthony welded the nut on for the last time, and if it had broken the stud again we would have been all out of room to weld to and off to a machinist we would have had to go. Luckily for us when it came down to the wire the weld method was a success. As always, thanks to Anthony! See you next time!