When trying to change out my pipes after I heat wrapped them, I had to remove 3 of my exhaust port studs! 2 studs came out because the nut wouldn't come off and instead just unscrewed the whole damn stud, the other one broke off and nothing was working to get it out, including the ez-out removers. So I had to drill it out. About a 1/4 inch into it, the drill bit broke off in the stud! I learned later that it was because I was applying to much pressure and drilling at too high of speed. Then it became a huge disaster and I couldn't get through it. I tried a few different things and finally started makings some progress with some cobalt bits and then finally punched through with some new cobalt bits that were sharper. Eventually I got it all set and re-tapped the hole and put in some Heliciol replacement threads.
Now, problem is that the new hole I drilled and the new stud, didn't go in the exact same spacing and angle as the stock set, so the exhaust flange didn't fit. When I went to take the stud out and try to take the coils out and adjust the hole, the damn hole cracked, and actually broke off a small piece from the bottom of the exhaust port stud hole!
So how do I repair this? Is the exhaust port made of aluminum? JB Weld did not work.
This problem is on the rear exhaust port on the bottom rear stud hole. 2010 Sportster.
Seemed simple enough and turned into a disaster!!