R1100RS exhaust manifold stud centres

[methamon]

Hi, I have had an attack of dreadful exhaust manifold stud corrosion; so bad (after 140,000 miles) that there were practically no nuts left.

The studs are also in shocking condition and predictably they are not going to unscrew without shearing off.

The bike is a R1100RS 1994 model (I understand there may be variations of stud position??????)

I have resigned myselft drilling and re-tapping (or helicoiling if necessary or possible) and to assist I need the positions of the three studs relative to each other. Failing that does someone have a crappy old header pipe they can remove the flange from and post to me (Reading UK)? All expenses reimbursed.

Regards

[capedoryus]

I feel your pain in that I just did a head gasket change. I live in a very corrosive environment and found the same on my 94. The dome in the nuts was rusted through and you could not see any threads on the stud.What surprised me was that the nuts came off the studs and the studs were reuseable. Here was what I did. Dremmel type tool to remove as much rust as possible with a small wire wheel and then lots of penetrating oil. Soak for a few days and repeat. The only reason I am posting this elementary lesson on bolt removal is that I was shocked to see rusty bolts on mine move and that the stud was OK. Good Luck

[methamon]

Thank you but alas there is no hope of the studs coming out easily. I have had the oxyacetylene othem until they glowed. I hit the ends repeatedly with a hammer to shock them and no go!

They have to be drilled out so I need a template to make a drilling jig preferably before I remove the exhaust system again.