Triumph TT Legend, "Jurassic" Exhaust Studs !

Here we go again, 6 corroded exhaust studs, 20 years of decay, Oh Joy.!
Patreon Link:- / delboysgarage
Like many busy channels these days, we support what we do here with the generous help of Patrons who make this channel possible.. we commit 60 hours a week to what we do, and make every video a polished production worthy of our viewers time and support, We also strive to pass on information and knowledge that our viewers can use to save them selves money and keep their bikes safe on the road too..
If you would like to join the team and help support our online activities, if you have maybe been helped and guided by our videos, or maybe just entertained.. then you can do that from just one dollar a month by clicking the link above and becoming a Patron of the channel... Thank you all so much for your support..
Alternatively If you just want to say thanks for this video alone, you can drop a dollar in our "Tip Cup' by using Paypal to [e-mail] The money will go to make more videos and keep this channel in your hands and not the advertisers.
Spanner Monkey Tool Site :-www.spanner-mo...
Buy 'Delboy's Garage' Merchandise:-
stores.clothes2...
Wiha Tools available from RECON Electrical :-
www.reconelect...
Primecooling :- www.ebay.co.uk...
Follow us on Facebook :-
/ delboysgarage
Check us out on Twitter :- / delboysgarage
..and if you haven't already, then please subscribe :- / moonfleet41
Become a Patron and join the team :-
www.patreon.co...

[@ChrisTiney-q4q]

Hi Dellboy, so I have just managed to get all 4 exhaust stud nuts of my 95 Dyna wide Glide by using the same kit as you used in this video . Very pleased as I can actually still use the studs. Thanks again for the advice and also thanks for all the other advice from your great videos. Cheers. Ride safe. Chris.

[@Moonfleet41]

Most welcome Chris, im glad it could help you out.. !

[@tigertiger1957]

The rusty coolant issue had already been mentioned here but in addition to the steel cylinder liners being a source of rust, the cylinder head bolts can also contribute. The bolts pass through the water jacket and can rust, especially where the threaded portion and shoulder meet, right where they screw into the upper crankcase. If the coolant change regimen is really badly neglected, these bolts can corrode so badly that they’ll snap when you got to undo them. Understandably, this is a King Kong sized pain in the arse to rectify, so changing the coolant every two years is a must. It’s also a lot safer to use an ethylene glycol based coolant, as the newer OAT type coolants have been known to delaminate the O/E head gaskets too.

[@toddcollins4920]

I bought a 2000 Legend TT with only 7300 miles on it in March so your videos are very timely for me. I've really enjoyed this bike although I re-jetted the carbs after throwing on pods. That was a trick modifying the bike to leave enough air box to mount on the chrome "900" covers.

[@fredriksalmen5159]

I did a similar thing, cut the airbox completely open, added a K&N filter, 3-1 exhaust and re-jetting. Went from the stock ~65rwhp to 82rwhp.

[@jonathanbrown1120]

Using an electric impact drill on low setting and working it up more and more is your best bet. The shock it gives the studs helps break them free without snapping them.

[@madmarkuk1]

Whoop whoop glad they all came off in one piece Del

[@philmorrow2446]

Ah, grasshopper! When you can remove exhaust studs, you are a Kung fu mechanic!!!😂😂😂. Nice one Del. A lesson in patience.👍🏻👍🏻👍🏻

[@ketoandyuk4816]

Really enjoyed that, I like it that you show the footage where it goes wrong.

[@alexfaulds7070]

Bravo mate, thought that last one was going to spoil the party.

[@Moonfleet41]

Me too Alex, a few silent prayers got said during that 45 minutes mate..!

[@Eight20]

Exhaust studs, the pain of every home mechanic! Heat is always the best option.

[@popscyclep8084]

I believe Heat is definitely the catalyst. However those other agents were absolutely required. Testy buggers!

[@roscoau]

Stainless steel studs in an alloy head. What could possibly go wrong?

[@CookingwithChefDai]

Evening D & P. I hope you’re both well. What a gem of a video. Some really useful golden nuggets I’ve learnt today. That last stud was a proper stubborn bugger wasn’t it!!!! Take care xxxx

[@Moonfleet41]

Good evening Chef, yes indeed a stubborn little bugger for sure, but well worth the time and patience to wriggle it out. have a good weekend brother, and keep safe.. D&Pxx

[@JDnBeastlet]

Nice work on the exhaust studs, Del. 6 for 6... a win for the patient approach!

[@garya3056]

Speaking of Legends, you are one, Del! Your patience is amazing. Thanks for letting me and the rest of this community learn from you. . Have a great weekend there, both of you. Will hit 103 heat index here Monday! 🏍👍🏍

[@Moonfleet41]

Hey Gary, 103? That's ridiculous, I don't think we get that more than once a decade! Have a great weekend and ride safe in the sunshine, D&Px

[@garya3056]

Delboy's Garage - I think our upcoming elections are making it feel even hotter, Del...😬 BTW, looks like 150k subs is around the corner!! Be safe...

[@SamuelCaballero1996]

Como siempre aprendo de tus trabajos , saludos !!

[@Moonfleet41]

De nada, señor, me alegra que disfrute de los videos.. Del.

[@cbsakias]

Nice procedure ,nice work,thanks for the free lesson,we waiting for more!

[@michaeljohnson-li5nn]

Del, I always change the coolant in my venerable old Goldwing GL1100 every two years, and refill using Type 2 Honda brand ready mixed coolant. The old coolant always runs out very clear but I think that’s down to adhering to regular changes and flushing the system out before refilling. As for removing heavily corroded nuts or studs, no matter how many you are removing, there is always ONE that will be an absolute pig to get out! Good luck with the rest of the build.

[@andyjrichie6709]

Just takes time getting studs out , well done

[@FREE_PUREBLOOD333]

Great video again. You have a lot more patience than me. :)

[@indianscout1019]

A masterful job Del (and that's not the beer talking!) I was just waiting for that sickening click as one of the studs went loose and snapped - Well done, 45 mins on one stud is what i call patience!

[@Moonfleet41]

Thanks mate, the last one was a mini adventure for sure.. !!

[@mattoeemeli]

Oh man, what a thriller! Nice Job Del.

[@Moonfleet41]

Many thanks mate, it was a good day!

[@fulsten7284]

Rust can come from the outside of the cylinders liners since it's in contact with cooling. And, this radiator is not in aluminium ? I've never seen a steel radiator. Great video.

[@DonHutchins]

Wow, I never would have bet on those studs/nuts coming out without at least some of them breaking. That's great! Looking good Del... looking forward to seeing all this come together.

[@Moonfleet41]

Thanks Donald, the last one was pretty much destined to break, but 45mins of patience nursed it out!

[@EdgeDynamicsEnglishRazors]

I feel liberated watching that deconstruction ..Nice job..

[@gordonwood608]

just got my self a 1997 thunderbird and watching you as give me the confidence to have a go at some of the tasks that need doing to tidy her up .

[@rl3898]

You may not be that pleased with that idea....Stainless is a devil for galling and jamming worse than a lot of years of rust. And will be almost impossible to drill out. Just change the standard material bolts more often !!

[@leaulife569]

Thread cleaning nut works better with a gap cut with a hacksaw through one of the flats.

[@crasbee]

You could put a magnet into your coolant pan and see if anything sticks to it. Rust particles are usually still magnetic, because there's still bare iron inside.

[@ozbusa]

"positively hysterical to drill out"... Best comment ever.. Made me giggle as I watched this in bed Sat morning.. 😝

[@Nissankingcabute]

Great vid and nice to see and hear you in a longer video.. I've been watching you for years and now my boys are getting into bikes, I've recommended your channel to so many bikers here in new Zealand.👍👍

[@Moonfleet41]

Thanks Andy, thats very kind of you mate, im glad you enjoy the videos, and really appreciate your support mate.. Ride safe and have a great weekend.

[@OutlawEdge]

We were here rooting for u on this crazy project bro! Awesome! Patients wins every time! 👍👍👍

[@Moonfleet41]

Patience indeed Brother, the most nervous 4hrs of the build so far!

[@gerry9359]

Hi Del great video love the fact that you managed to get the exhaust studs out in one. Waiting for the next installment. You and Penny ride safe and stay safe

[@Moonfleet41]

Thanks Gerry, glad you enjoyed it, lots of fun that one, if maybe a bit nerve wracking .!! take care and keep in touch.. D&P x

[@LenScapoff]

I must say as the owner of a 2002 Thunderbird from new that's still pretty immaculate, it saddened me to see the state of those headers and fasteners. These bikes were built like tanks and just need(ed) sensible maintenance. Still, I'm enjoying your project. 👍

[@andyjdaviestjk]

Nice prep it's the same with any job, good preparation and patients saves so much hassell something I was always taught but sometimes forget when you work on the bike you ride every day. Well done mate nice work

[@bobflemming9105]

You've got some patience Del, I would of give it some and ended in a nightmare. Haha Good job mate. Liking this project. 😁

[@prophaniti1]

Had a thought, next time you pull bolts out of the radiator like that run the bike up first nice and hot so the rad has expanded, they may cone out without snapping.

[@rsbharley4766]

Nice one Del, you had a win mate. Patients is a virtue and heat is your friend, well done. Penny and you have a good weekend and stay safe, hope things are getting better over there. Cheers

[@Moonfleet41]

Hey mate, thanks for your kind wishes, weather's up and down now, nice today but wet tomorrow, so pretty much back to normal for Blighty! Have a good weekend yourself mate, ride safe, D&Px

[@arnybarmy]

What a result! Just ordered some Aerokroil! Have a good weekend both of you.

[@richardpearson4248]

Great video looking forward to next one stay safe 🇬🇧👍🏻

[@topschrott7112]

Sauber gearbeitet, bin begeistert. Dicken Daumen hoch!

[@sqward]

I've just snapped a hex bolt on my bike. Very disappointing first venture into working on my own bike. Great video. Being patient and methodical must be the key.

[@mattmckee396]

I can’t believe those came out. Amazing. Time and patience well done sir

[@jamievandalen]

that was therapeutic to watch.great job as always del!

[@haroldwiser2641]

It's hard to believe those bolts and studs came off, I would have broken at least half of them!! Excellent video 👍 You and Penny have a great weekend!

[@Moonfleet41]

Hi Harold, I think that was a lucky break (well, 6 lucky breaks in fact!), and am still waiting to get my bad luck probably further down the line! Have a good weekend yourself, stay safe, D&Px

[@springy-2112]

Buckaroo ! you deserve a win brother after the busa bolts !! Great viewing a welcome relief to hanging chain blocks off I beams 300ft up in the sky !! only 8 nights to go then a week off ..yipeeeee! Peace and love brother 👍🏻☮❤

[@Moonfleet41]

Buckaroo? More like Operation maybe! Good to hear from you Brother, take care at them heights, I get a nosebleed in two pairs of socks lol Have a great weekend and enjoy the sunshine! D&Px

[@adnanlatif1722]

Dell your work is flawless

[@andigossweiler1551]

Never ever use stainless steel studs as exhaust bolts. Stainless studs in aluminum are prone of corroding and can never be removed, especially exposed to heat. Use normal steel grade 12.9 inbus (allen) bolts (the black ones), cutoff the head, and mount back with copper plated steel nuts, use ceramic paste.

[@paulharast1958]

Awesome job I'm taking the parts apart. And I like your little tips and whenever I work on my motorcycle and come across a rusty bolt I'll remember what you said to do. And I think it's an excellent idea to replace that radiator because the bolts broke on the inside so why do you want to waste your time to try to get out the broken bolts.Del & Penny Ride Safely and have A Wonderful Week

[@Moonfleet41]

Hi Paul, yes I think a new radiator is an investment in the future, and even though it's a low mileage engine, I think flushing it every year would be a wise investment too or either that, or invest in waterless coolant as so many classic car owners do. Have a great weekend yourself, enjoy the sunshine, ride safe, D&Px

[@RenchRanch]

Good GAWD that poor bike! It's in good hands now. So much rust and corrosion. I can't believe the state of all that stuff. Also the backbone on that frame is INSANE! LOL I have never seen a backbone steel tube that massive on any bike. Interesting project for sure Bro. Can't wait to see how it comes out. Cheers! Mike & Melly

[@Moonfleet41]

hey Mike, how are you both doing.. we must make time to catch up properly aye... The backbone frame is kind of a throw back to the old Triumphs which carried the engine oil in there, the filler cap was at the back of the tank right next to your nuts... great British bike design at its best brother... take care and have a good weekend, Love to Melly, chat soon. D&Pxx

[@paulmessenger1006]

The rad will be fine. Rust is from barrels (wet liner) pump impeller or most importantly the head bolts, they can be known to corrode and snap. Primarily exhaust side on #1lowest point. Didn't see you drain the block. Stainless dome bolts on studs are the answer.

[@Moonfleet41]

Yeah, so I'm hearing, I may switch over to waterless coolant for this one, if there's so much ferrous metal internally to cause problems, it's the weapon of choice these days for many vintage and classic car owners with precious ancient engines... dome nuts is a great plan, possibly copper nuts too, the studs won't rust this time being stainless, all details for the future.

[@paulmessenger1006]

@@Moonfleet41 no need for going crazy. I just use Rock kool. No problems. Usually with triumphs 1st thing you do is check coolant. If like drinking choc walk away.

[@robftz]

Awesome Mate.!!! You are great.!

[@waldemarb.5136]

Hey Del, I probably discovered where the rust is coming from. I put out the steel pipe from the radiator to the pump. It's full of rust

[@Moonfleet41]

It is indeed, but I think there are suspect internals in these engines apparently that also cause a lot of rust!

[@ollieb9875]

If you're going to get a new rad, cut the old one open, let's see what is inside! 😁

[@Moonfleet41]

That's a good plan mate, run it through the band saw maybe?!

[@ollieb9875]

@@Moonfleet41 hehe 🙂 that would do it, or the angle grinder eh, seeing how adept you are with that thing 😁

[@dcads2290]

Dont ya just hate it when u snap ya nuts. Great vid

[@nickbishop6784]

Nice one Del You've got the patience of a saint. Great result though Look forward to the next video Nick

[@Moonfleet41]

Glad you enjoyed it Nick, and no point in rushing or becoming impatient, it only makes life harder in the long run when you have to drill out the stumps!!

[@istvanvigh2367]

Congratulations! The rust dealt with the machine, you the rust!

[@Moonfleet41]

You said that right!

[@yammietomogrady1322]

Prep and Patience .. Great job.

[@titchness8487]

Check the water pump before you chuck the radiator! Found steel water pump rotors in an apparent Ali casing before. It's worth a look at the pipe work too, chances are they're steel

[@Moonfleet41]

Yes the pipes are steel, certainly the one I took off, and easily replaceable, may well take a look at that pump, cheers mate.

[@jonathanmellish4439]

You lucky talented fella. Mine are worse than that on my 955 and i know what fall apart.

[@popscyclep8084]

Takes a Stud to deal with a Stud. Great Video!!

[@Moonfleet41]

Post of the day!

[@popscyclep8084]

Delboy's Garage Just calling it what it is Sir. ;D

[@cyberjack]

I thought for sure they would snap ..lol ..

[@innes59]

Good job mate and close thin not snap 👍

[@fredriksalmen5159]

Very nice, amazing patience, I usually flipp out and breake something 😄 Will be interesting to see what exhaust you come up with, I guess a 3-3 or 3-1? Are you planning any engine mods? Like 750/Super 3 pistons and "green" cams (most of the other early Hinckley)?

[@Moonfleet41]

750? It's a 900 already, and what about a high level Scrambler stylee 3-in-1? All depends on whether I can make it happen Fredrik, never built an exhaust before!

[@fredriksalmen5159]

@@Moonfleet41 Of course you can make the exhaust, you seems to be able to make anything! A scrambler style would be cool I think but I prefer something more racy looking unless it is gonna be a scrambler, looking forward too it! I should have explained the pistons better, the early 750 Hinckley bikes have same bore but shorter stroke and high compression pistons. Some people have fitted those, as they are a direct fit, and reached >100rwhp together with "green" cams from any of the other bikes from same era (except Super III which had "red" cams I think). Thinking of doing it myself, but I'm actually quite happy with my 82rwhp (over stock ~65rwhp) I have now using open airbox, re-jetting and 3-1 exhaust :)

[@ronlheureux7623]

For what it's worth, I recently watched a KZbin video where, as a last resort, an impact drill/driver was used on stubborn rusted bolts. The theory is that a sudden, abrupt shock of torque will often brak said rusted bolt free. I am from a dryer climate than you have is the U.S and rust that sever as I've seen on several of your project bikes is uncommon. I've been watching a KZbinr that collects non-running CB Four models, like the 350F, the 550F, and the 750Fs ) from the early 1970s and gets them running after they have sat for as long as 35 to 40 years. (They are very popular to collect and restore in the U.S.) While there is a somewhat rusted bolt, the rust isn't caked on like your bikes. Even you later model Harley's have a serious amount of rust. Is that due to all the rain that you get over there, or do they use road salt? (The road salt does seem unlikely to me). We do see a tremendous amount of rust and corrosion on vehicles from the Mid West and East Coast, where they salt the roads every winter. Thank you for your fine channel.

[@Moonfleet41]

If all you need to do is break free a frozen bolt that's internally healthy, then an impact gun is fine, but when bolts are this badly corroded, the integrity of the fastener is compromised, and whatever it's original torque setting may have been, would now be more than enough to snap it clean off... it's simply physics, when the twisting force you apply to the bolt is greater than it's ability to resist it, and when the grip on the thread is also greater than the bolt's ability to resist it, then it's guaranteed to snap, and if you're applying impact on top of that, then it'll certainly snap... with fragile bolts like this, the only safe method to remove them, if even possible, is gently persuasion and working them backwards and forwards to gently free up the grip of the thread, constantly working under the torque level of the bolt's snapping point... and yes, we salt our roads every winter here and then the moderate, temperate climate we have, it's fairly wet as well... and don't forget Ron, the manufacturer's stupid decision to fit mild steel studs in the first place! Thanks for your kind comments, have a great week there!

[@HalfdeadRider]

I got lucky when I changed my exhaust gaskets, the studs all came out with the nuts. I had purchased new nuts, but not studs, so the old ones are back in for now 😎

[@kyle2109]

Del, another great video. Though you do tend to make it look too easy. At the very least keep a spray bottle handy to hit your face with and make it appear you’re sweating it! And, I will comment again on the quality of your videos, which lend smartly to how well the instruction comes across. I wonder if some day you will let on to us the false wall in your workshop, that hides behind it a full studio with camera crew, production assistants, directors, and editors!

[@joepie221]

As we like to say around here, " Check your shoes" you must have stepped in shit on the way to the shop. Not sure what you did to deserve such a break, but don't change anything. Way to go.

[@Moonfleet41]

ha ha, i didn't hear that one before Joe, thanks for the smile... picked up a bakers dozen of patience and a sense of humour on the way too.. that last stud took 45 minutes to work free..! now i feel epic and will have a better weekend for sure.. take care and be safe Sir... Del.

[@holt8887]

Hi del wen you was taking the rad side covers off and the allen key started twist well i was changing my gear position senser and the ball off my allen key as snaped in side the bolt any idea's on how i can remove the peace of allen key with out damaging the bolt or a vid u av done what i could watch thanks john

[@Moonfleet41]

Hi mate, i must say ive never had that one happen, those ball end keys are a bit more fragile than the regular keys, but then often thats all you can get in the space... if i was facing that, then id probably try tapping it gently each side of the broken bit with a sharp centre punch and see if you can dislodge it, maybe a little penetrating oil around it to help break the grip.?.. hope that helps in some way mate, all these things are trial and error when you're stuck in a fix..! Good luck with it mate ..

[@holt8887]

@@Moonfleet41 cheers del al give it a go

[@szbalogh]

This poor bike is in much worse shape than mine was after 15 years standing. Cylinder liners are steel, radiator is aluminium. If the coolant is to old and anti-corrosion components are broken off those metals will eat each other. I had to replace the radiator, bought the chinese one from UK. Works well so far. Also had to replace the head gasket. There was a thick sediment around cylinder 3 where coolant flowing slower/making more turns, working as a settling tank. No way to flush that out without taking off the head. Here is the story of my Legend ;) www.triumphrat.net/threads/legend-tt-99-repair.955612/

[@stevegrim]

Those four hours are one reason I don't pay a shop to work on my bike. They would just stick a socket on the nuts and turn them. If they break......they break. More money for the shop drilling the broken studs out. Do it yourself and you can take as long as it takes to get them out.

[@Moonfleet41]

Exactly mate, and your own time is free aye.

[@peterjobson3860]

Good job that was damsite easier than the Hayabusa

[@patrickcollingwood4613]

Ya 🤗 that was mad well done Del u were so lucky good on ya 🥵

[@stevet9487]

What more can I say 👍

[@han_mulders]

Still like this build a lot mate! Since the last few video’s I seem to notice that you upped your presentation a bit, am I right? It feels a tad more like an ‘official show’ in a good way 👍🏻👍🏻🏋🏽

[@Moonfleet41]

Thanks Hans, that's only something you can determine and if you take the view it looks better and more professional, then I really appreciate that, just keep moving forward and try to do the best with each video... perhaps practice makes you a little better at something with time! Many thanks for your support.

[@wojtekb62]

Hi Del will you replace those studs with stainless steel ones or OEM?

[@Moonfleet41]

If you were restoring an old MGB would you use crappy Leyland parts, or modern reliable parts..?

[@loddude5706]

Yep, clean off remnants of rust & baked-on road-kill, a quick 'cringe' of thermal shock, then 'Kroil' & go make a cuppa. Impatience is a no-no, go bash something else for 20mins; given time that stuff has more creep than a Royal flunkey : ) x

[@KMaC-wt9lr]

My praying for you worked.... 😁

[@Moonfleet41]

ha ha, it was you then was it ?.. thank you my son, and bless you for your prayers..!

[@robertgwinn8406]

Cool

[@MikeButler05]

Ahhanother educational vid , like you say take your time and you may get lucky , out of the products you used which would you say helped the most ?

[@Moonfleet41]

Without doubt, the greatest asset is Patience, without that, all the 'products' are useless.!

[@mrstevepace]

Good job Del 👍

[@michaelmclachlan4278]

Tip of the hat to you Sir

[@renyardfox8227]

Is it beyond the wit of manufactures to make exhaust studs that dont corrode so much?. With success like that Del you ought to go and buy some lottery tickets.

[@Moonfleet41]

You'd think wouldn't you?!

[@Richard-pe4cx]

i bet your were glad it was only a 3 cylinder bike

[@Moonfleet41]

Yes indeed, grateful for the two I didn't have to do!

[@HONMONSTER]

Good Job Del.

[@ashwfuller]

Where did you order the studs from? I need some for my bonnie before they become a problem!

[@Moonfleet41]

Ebay special mate, just threw out a search and went with the best deal available, about a tenner for the lot.

[@merquisonmototardivo5806]

Perfect

[@mattyreid2261]

Nice one del👍

[@danielparker-hales245]

Turbo build? 🤔

[@Moonfleet41]

Naah, got a Hayabusa for that.!

[@geraldgallagher825]

Did you go out afterwards and stick on this weekends lottery m8 ? Lol

[@mudmucks]

What torch attachment are you using?

[@andigossweiler1551]

And yes, radiator fins are never out of steel, impossible. Either cooper or aluminum. The rust must be come from the steel sleeves of the cylinders, like Fulsten already mentioned.

[@andreasp.marinos1173]

opened the water pump, it is definitely full of rust.

[@andydawson2070]

Patients is a virtue, glad you took your time with them.

[@mattmcevaddy]

Stud removal trick worked well. Thanks for sharing!

[@shaneelson]

Well done Del. Had me on the edge of my seat with memories of the 'Busa. Patience is rewarded 👏👏👏👏

[@GrandpaFumblefingers]

As an old wrench turner, I have to say I am impressed at the patience you showed with those exhaust studs. . Heat cycles and road mung, Steel and aluminum, age and mileage., then throw in impatience. A formula for disaster and you were only missing the high mileage & impatience. Good Show.

[@Moonfleet41]

Thanks mate, I think this is one of those perfect demonstrations of where patience really is a virtue... plus, of course, as you will know yourself, a fair bit of experience at knowing what they feel like when they're about to snap and being able to stop short and go back the other way!

[@bosscat8951]

You should replace with stainless studs but use brass nuts not stainless nuts.

[@Moonfleet41]

Thanks Toby, I've heard copper is even better.

[@bosscat8951]

@@Moonfleet41 yes copper works too but not as strong as brass so the nuts need to be longer than 1.5 x d. Never will you have trouble undoing them again. ☺

[@oogabooga7882]

exhaust nuts commonly vibrate loose on my Harley. will begin to rattle more and more loudly and soon will fall off if i don't stop and tighten. i've learned to carry extra nuts on the road. first time this happened i fixed a lot of things that was ok before i found the problem. that rattle made me crazy. 😂

[@Moonfleet41]

Try copper nuts on your Harley headers.. they don't corrode in place, and won't rattle loose either..!

[@chrislowes1335]

Stainless steel studs and nuts once tight will be very difficult or impossible to remove unless anti seize is used when assembling. The reason is that they gall each other upon tightening. This has been known about since ww2 you have all been warned! I worked with stainless Steel for years especially 316. Stainless is softer than decent mild steel. Well done getting those header nuts off.

[@mattmcevaddy]

great job.. I have one broken stud on an FZR 250R 1989 cylinder #2. Resisting all attempts to be removed. have about 10mm of it remaining, but threads are well gone!. I'll give these techniques you shared a go! thanks!

[@OriginalUsername9000]

Have you ever tried dissolving broken/stuck bolts out of aluminium? Apparently it can be done with a hot solution of alum. For something big like the radiator it's probably too inconvenient but for something smaller it might work great.

[@gilesbristow123]

Coolant looks ancient but maybe someone has used the modern OAT based stuff which has a strange cloudy almost translucent look? Just a thought as it's odd looking stuff to us old school types