Stripped Header Bolts

[Schuy]

I went to pull the exhaust of my 99 warrior and found the bolts on the exhaust header were quite rusty, so i used some bolt loosening compound (can't remember what it was call weird name) This however didnt work and dispite my best efforts to prevent it one of the bolt heads snapped off and now I need the best way to get it out...any Suggestions?

[Demon Rider]

That sucks. Is there enough left to get some vice-grips onto? If not your going to need an extractor. Can be picked up at Princess Auto, Canadian Tire or a similar store.

[huseman015]

hey whats up guys. if you can not get that bolt out i would try to heat it up then take something small and hit ot out with a hammer. thats what i di. but anyways whats up?

[Demon Rider]

Yeah you could try to heat it up. When you do it though make sure you just heat up the area around the bolt, but not the bolt. The idea is to make the hole expand and keep the bolt the same size. Thats what makes this trick work. I would try to avoid using a hammer because you don't want to hurt the threads that are in the hole. Otherwise you will have to re-tap them before you put a new bolt in.

[Policy Peddler]

Take a nut that is approximately the same size as the stud. If the stud sticks out slide the nut over, if not use one with the hole a little smaller than the stud if not, use the same size,
Now take a Mig/wire welder and weld the center of the nut to the stud.

Now take the appropriate wrench and turn the stud out while it is still warm.