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[briang1344]

So...here goes the story. Part1: Took pipes off, threads on stud were gone. Part2: Borrowed a stud remover, SNAP! Right at the head. Part3: neighbor came over, drilled out the broken off stud and managed to drill into the exhaust port.
Part4: oh chit.

Wondering what a guy should do? Tap the threads let it go, or weld it up?
   Just lookin for some ideas and/or Places to send that head. Thanks!
 
 

[HD Street Performance]

I fix them all the time. I have a head holding fixture on the mill that allows the heads port and studs to be aligned straight to the spindle. I center over the stud then mill out slightly undersize on center The broken stud. I then remove the remnant of threads left. Run a tap in it and then good as new.

Another option
Jims makes a tool for on the bike repair

[TorqueInc]

  I use a time sert to repair them....anything is better than helicoils

[prodrag1320]

as long as the hole is where it should be,tap the hole & put a stud in it,it`ll be fine.if it needs a insert,use a heli coil,it small holes,1/2" & down they work just fine

[dlaws01]

J B Weld it. 

[phato1]

So...here goes the story. Part1: Took pipes off, threads on stud were gone. Part2: Borrowed a stud remover, SNAP! Right at the head. Part3: neighbor came over, drilled out the broken off stud and managed to drill into the exhaust port.
Part4: oh chit.

Wondering what a guy should do? Tap the threads let it go, or weld it up?
   Just lookin for some ideas and/or Places to send that head. Thanks!
 
 

Just curious, are you saying that you drilled it off center/crooked going into the side of the casting or are you saying you went to deep?? Makes a world of difference as far as repair options.

[HD Street Performance]

Have fixed them drilled off center and even with broken easy outs in them. As long as the threads are still there I don't resort to inserts. Otherwise do use helicoils.

[johnsachs]

If you in fact drilled through into the exhaust port(hole in port), just install a new stud or insert and stud with Loctite, and call it a day. It ain't "rocket science". 
John

[briang1344]

Drilled and tapped/helicoil installed. We'll let it cure and see what happens!
   Thanks for all the comments guys.

[HILLSIDECYCLE.COM]

I've seen E-Z Out's cause more harm than good over the years.
Only thing worse than having an E-Z Out snapped off in one of those stud holes is a high-quality high-speed steel drill bit.
Once any of those obstructions are removed, we install a Heli-Coil brand thread repair insert.
Installed CORRECTLY, they are long lasting, won't migrate, and the threads are of a higher tensile yield than the parent material.
Scott

[Ghost__Rider]

too late now, but Jims makes a nice exhaust stud removal tool. Works great.

[05Train]

Sounds like a good excuse to get a set of Baisley heads.....

[HD Street Performance]

 
An idea of how to do this

[GMR-PERFORMANCE]

Every pipe we take off gets some PB blaster before we start. Has proven to make the job go much easier if a stud is damaged some heat to the local area and double nut or weld nut to stud if threads are too far gone and remove.

Heli coil is a great fix and will hold if the job is done correctly.

Have a head here that has a small drill bit at a crazy angle broken and then the other side has a tiny EZ out snapped off. Not sure what the heck was going to get two items broke off in the stud hole..

 Into the mill with carbide end mill and cut it out.  We use a plate that we mount to a H/V moore rotary table. I have seen guys use a drill press and large angle plates to get the job done.

Heli coil locked into place very well.

Glad you got it taken care of

[porthole]

Heli coil locked into place very well.

What is the reason that Heli-coils seem to be the preferred fix over a threaded insert?