Seized / Snapped Stud Tips

[sparkywilliam...]

Hello chaps,

Two of the oil cooler studs have snapped in my mk2 bandit cylinder head and would like your best ideas of how i can try and extract or drill out.
At the moment access is hard as they are near the oil outlet tubes but i shall be dismantling the engine and re-assembling so worst case scenario is i will be able to take just the cylinder head to a machinist if all else fails.But i would like to at least try myself to gain experience.
A mechanic friend tried the welding nut trick but no joy.
Once i have cyl head off i am thinking of soaking them with plusgas,filing a slot,trying with a flat blade impact screwdriver but i suspect the crap metal studs will be like cheese.Then i assume it's helicoil time but i am unsure what kinda tools i need.They are 6mm studs.
I am going on assumption here so if you have a brilliant idea please let me know!

please see attached pics.any help appreciated.Thank you.
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Previously CG125,YBR125 Now GSF600 Bandit

[Minty]

Why you shouting?

Is there enough thread to get a nut on there and a blob of weld in the middle of the nut to fix it to the stud?

Edit, just read the shouty bit and you say the weld didnt work. How much thread is there?
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My fingers smell of your mum.

[sparkywilliam...]

Sorry didn't mean to shout,thought i was making it easier to read lol.
there's 3.5mm left on both.
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Previously CG125,YBR125 Now GSF600 Bandit

[Raffles]

Don't waste your time slotting the stud remnants. Such comic-book solutions rarely work.
You need to get drilling.
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A good loser will always be a loser.

[kramdra]

Ive tried everything on exhaust studs. Chuck/cam type removal tools need bigger diameter to grip, good waste of 30 quid. Drilling will be best, but do not try free hand.If your getting the head off anyway, it will be a lot easier. Hardened drill guides were suggested, but I could not acquire any. I also looked at making a rigid drilling jig to bolt onto bike, would have been a hell of a lot cheaper:

I got shop to do it, 700 quid for head and 200 quid machinist to do 7 studs. It also took them 3 months

[Pete.]

That's not oil cooler, that's a PAIR outlet (photo is upside-down).

Blast all that crap out of there then block it off completely you don't need it. I'd try chemical metal, doesn't really matter how you do it. so long as you do.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[sparkywilliam...]

I was going to say,my mistake it's the part of the PAIR system.

Pete,why do i not need it? are you saying that i don't need the pair system? excuse my lack of knowledge about this,i am a newb to this.

I agree,it was a 'comic book' wishful thinking on my part.
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Previously CG125,YBR125 Now GSF600 Bandit

[Pete.]

You don't need it because it does nothing for the running or reliability of your bike. It's sole function is to pump air into the exhaust to provide oxygen to ignite any un-burnt hydrocarbons. It's an emissions-controlling device (not to mention a royal pain in the ass when it comes to servicing time).

Fit the pipe or don't fit the pipe - makes no odds.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[sparkywilliam...]

So won't affect MOT emmisions? or have any issues getting it through mot?
in that case - i may as well blank off all the ports neatly as i can and not even bother fitting the main part where the ignition coils go.while i'm at it?
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Previously CG125,YBR125 Now GSF600 Bandit

[Pete.]

Bikes aren't emission tested, so not much chance of affecting it. Yes, junk the pair pump but be sure to block off the little pipe and the big pipe going to it from the airbox/carbs.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[sparkywilliam...]

lol ah ok mate well thank you very much!
One less thing to put back on the bike!
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Previously CG125,YBR125 Now GSF600 Bandit