Bandit 600 exhaust bolt

[Guest]

Hi all,

I am restoring an old bandit 600 to use as a commuter for work. The bike has been left standing for a long time and needs a bit of work doing to it.

When taking the exhaust bolts off 2 of the we're stuck good and proper! They would not move, this was after soaking them in penetrating oil, trying a little heat etc. we'll in the end the bolt heads snapped off and the bolt was left with about 10mm sticking out. I used a dermal to cut the bolt flush with engine and intended to install a heli-coil. I had a little (big) fudge up whilst drilling out the old bolt. I though it was going well so I increased the speed of the drill slightly and then it jumped north and has now made a mess of the area!

I have attached some photos to try and show what's happened but to explain as best I can the drill move up by about 3/4mm whilst I was drilling and now I have a overall shaped hole. Is this repairable? Is it anything a good welder could sort out? Or will I have to replace the head?

[eastanglianbiker]

welcome to the forum please pop into newbies when you get time and introduce yourself as it makes us feel a bit happier about ofering help and advice knowing that you might stick around as its one of the best forums you will find online.the pics dont appear to of come out for some reason so it depends on how far over the hole has gone you might be able to recover it with something like chemical metal or get it welded up and then drill new hole again

[Guest]

hi, thanks for the reply.

Sorry your right I should have said hi first.

I have tried to re-post the images.

http://i566.photobucket.com/albums/ss107/buy_my_cookies/IMG_23841.jpg

http://i566.photobucket.com/albums/ss107/buy_my_cookies/IMG_23831.jpg

http://i566.photobucket.com/albums/ss107/buy_my_cookies/IMG_23821.jpg

*edited to sort out the pictures*

Edited September 7, 2014 by Anonymous

[Stu]

Pics are hard to see on mobile!

But the good news is you don't need a new head I know of worse that's been repaired

You may still be able to get an insert in and it may hold

Are you putting bolts in or studs? Personally studs are miles better then use brass nuts that way if they seize again the brass nuts snap leaving the studs intact

Anyway as for repair if it's too bad then you can get it welded and drill and tap it

[Guest]

Are you able to suggest what inserts may work? To me it looks like ive done to much damage to get one in.

I have added links to the images in the hope this shows the damage better.

http://i566.photobucket.com/albums/ss107/buy_my_cookies/IMG_23841.jpg

http://i566.photobucket.com/albums/ss107/buy_my_cookies/IMG_23831.jpg

http://i566.photobucket.com/albums/ss107/buy_my_cookies/IMG_23821.jpg

[Stu]

Hmmm Yeah they are a bit of a mess aren't they

I would get out what's in there get them welded up and start again

I wouldn't bother with an insert on them looking from here I would drill and tap once welded then use some stainless threaded bar

[Chrissb6]

Hi and welcome, where are you located? I agree with the rest, get the rest of the steel out and get it welded up and start afresh. You may be lucky and find someone who can tig weld that up in situ. If you live anywhere near Nott's l might know just the man.

[Guest]

hi,

I live in Wisbech (PE14) but work in Peterborough. The engine is off the bike now so I can take it some where if needed - if any one knows a good place in my area id really appreciate it, my welding experience is only some simple stick welding and im not very good at it!

Also has anyone else every had something similar done and have any idea how much it cost them?

[Stu]

a mate of mine had his blade head welded as he cracked the surrounding area

it cost him around 50 quid

[eastanglianbiker]

as you are in wisbech pop into fenland choppers down tinkers drove or into guildos down weasenham lane