Gday
today i was taking the exhaust manifold off of my vl commodore to put extractors on it, when the exhaust bolt broke off, as you can imagine there was some very colour full words said for the next 10 mins. how and whats the best way of getting it out???
its a alloy head so is there anything i need to be careful with???

thanks

hi it will be grown in there lucky if it will wind out, i use this method on exhaust studs, usally the stud rusts and locks up the thread.
make sure the end where it is broken is flat, if not use a barrel ball style die grinder bit 3/16 diamater and make a divit in the centre,then go buy a 1/8 cobalt sutton drill bit, on another hole in the head mark the drill with some tap, last thing you want to do is go into the water jacket,theres not much metal at the bottom of the vl head till you reach water, drill CAREFULLY through the centre of the bolt you will feel it break out the back of the stud then STOP, i have in my tool box a 3/16 1/4 and 5/16 barrell ball end die grinder bit use the 1/4 and follow down the drilled holed use some crc once through enlarge the hole till you can see the back of the threads of the stud, do this in a couple place and the stud will be weak enough to colapse with vice grip or small flat blade screw driver, vl studs sort of crestizile (go hard) from the heat and snap replace all of them with new last thing you want to is snap one doing it back up, if you not keen to have a go most major citys have a mobile guy that specialise in the stuff.
let us know how you go pete.

hi jim using that method above i can get them out in ten minutes, also with the studs out clean the holes out with a tap and use some form of anti seize on the studs goin back in,