Sheared off bolts on exhaust bracket!

[Shropshire_Lass]

Was out on the evo not so long ago and made a shocking discovery.

The bolts supplied by V&H to attach the rear bracket for the big radius exhaust have sheared off. These leaves the exhausts with no support (i'm amazed that it has sheared the bolts of the exhaust ports on the cylinders!) and the remainder of the bolt stuck in the frame.

Does anyone know what I could do ............. would it be better to try and remove the remaining bolt stems from the frame ...... and if so ..... how?

Or would it be better just to drill the holes our completely and buy a chunky nut and bolt job?

Also ..... so you think there is justification for making a claim against V&H for supplying shit bolts?

Any help much appreciated.

Cheers
Ruth

[girlyglide]

Originally Posted by Shropshire_Lass

Was out on the evo not so long ago and made a shocking discovery.

The bolts supplied by V&H to attach the rear bracket for the big radius exhaust have sheared off. These leaves the exhausts with no support (i'm amazed that it has sheared the bolts of the exhaust ports on the cylinders!) and the remainder of the bolt stuck in the frame.

Does anyone know what I could do ............. would it be better to try and remove the remaining bolt stems from the frame ...... and if so ..... how?

Or would it be better just to drill the holes our completely and buy a chunky nut and bolt job?

Also ..... so you think there is justification for making a claim against V&H for supplying shit bolts?

Any help much appreciated.

Cheers
Ruth

I would contact V&H and see if this is a known issue, although I haven't had any experience of the bolts failing.

Did you buy the system in the UK or USA? If in the UK then you need to contact Mag Europe, any problems finding their number let me know and I'll give it to you.

To repair remove the remainder of the bolt from the holes in the frame using an easi-out or similar and replace them.

How old is the system?

With regard to "shite bolts" it's a little subjective and they would probably not take too kindly to having them described as such. They could argue incorrect torque setting used for example to explain the failure. Best bet is nicely, nicely, catchy monkey.

[kiwidave]

If you can take the bracket off, then do so, Ruth.

Got a mate working at an engineering workshop nearby? Take it to him/her and give them a few quid and a bottle of Scotch or something.

DIY?

You will need to go to a good hardware store or a tool specialist and ask for an ''EZ Out'' or extractor, which you may be able to buy individually, or in a set.

They are funnel shaped reverse-thread bits. Very hard.

With a TOP quality diamond/titanium tipped drill bit, you drill a hole into the bolt / screw. Go slow and lube the drill bit with water. Max revs from the start will see you quickly turn the end of the bit blue, blunting it. Then you need another!


With the hole drilled, carefully wind in the extractor (which has a smaller initial diameter than the hole, and quickly flares out) using a TAP HANDLE for safety... Then you use it to twist out what is left of the screw. The reverse flutes on the extractor cause it to bite harder into the metal of the screw as you put more force on it. Screw extractor bits are made of very hard metal, so they are very brittle.

WARNING: It is very easy to break one off inside the screw. When that happens you are screwed - the extractor metal is harder than any drill bit, so you can't drill it out. The only solution then is an engineering workshop and ''spark erosion'', a specialist technique. It may even be cheaper to buy a new exhaust bracket in that instance....

The bolts we are sometimes supplied with, with our parts, these days can be Taiwanese junk. Get top quality replacements.

[girlyglide]

Originally Posted by kiwidave

If you can take the bracket off, then do so, Ruth.

Got a mate working at an engineering workshop nearby? Take it to him/her and give them a few quid and a bottle of Scotch or something.

The bolts have sheared in the frame, not the bracket Dave. The exhaust support from V&H uses the stock exhaust hangar bolt holes.

[kiwidave]

of course. sorry..... makes it a bit harder job then.....

[Phil]

Originally Posted by Shropshire_Lass

Was out on the evo not so long ago and made a shocking discovery.

The bolts supplied by V&H to attach the rear bracket for the big radius exhaust have sheared off. These leaves the exhausts with no support (i'm amazed that it has sheared the bolts of the exhaust ports on the cylinders!) and the remainder of the bolt stuck in the frame.
Does anyone know what I could do ............. would it be better to try and remove the remaining bolt stems from the frame ...... and if so ..... how?

As I recall you have a Softail. If so & the stock bolts were used, then if you look between the frame & swing arm you should see a half inch or so sticking out. You can use some pointed vise grips to get them started out.
If they have loctite on use a pencil torch to heat the broken bolts up, NOTHING BIGGER than a pencil torch as you will burn up the powder coat. Once you get them started a reverse drill bit will turn them out. Exhaust mounting bolts are a fairly soft compound to cope with vibration. I would say they broke because they were over tightened.

Or would it be better just to drill the holes our completely and buy a chunky nut and bolt job?

Not enough room between the frame & swingarm for that. Of course if you don`t have a Softail, I`ll go lay down.

[Harleyfatboy7]

Set of 6 eazi - outs from Halfords for under £10, I had a similar problem with a sheared bolt in my frame (Footboard mount), It was a piece of cake

[Shropshire_Lass]

Hey everyone

Thanks for all the advise - having read Kiwi's section on the snapping of the reverse thread removal i.e. if it snaps yer ferked ..... have decided to take it to a local engineering shop who guarantee to fix it .......... they apparently deal with little mishaps like this all the time.

Seems more sensible than letting me loose on it - am happiest when I can use a hammer!