Exhaust Stud Came Off, How To Fix Aluminium...

Ouch; looks like a weld job, probably need the head off for repair but looks like it could be fixable

 

You can buy a liquid metal it's actually more like a two part epoxy putty that you can mold in place, but not sure if it will fix this as have not personally had any experience with it, but certainly worth a go as first step.
I'm sure one of the other more experienced builders/restorers on here will give you more advice shortly.
But as said may need welding. Good luck.

 

Hi and welcome. Can't help you, but I'm certain somebody can.. Knowlegeable lot on here.

 

Ouch! I have yet to have this type of problem, but would probably lean more for a weld solution for this. Maybe someone will come along with a little experience who can assist you. Good luck.

 

I would get it welded then drill and tap it

 

Did you get Foot Pounds mixed up with Newton Meters?

 

The break looks clean and fresh. This would lead me to think of two possible causes,
1, was the hole clean and dry BEFORE you put the stud in? If not this would hydraulically pressurise the tapped hole blowing the casting.
2, The stud is short or not bottomed in the hole and so overloaded the top few threads.

Liquid metal repair would be a poor option here especially with the fluctuations in temperature.
TIG welding is the only real option. The head will need removing and then a plan devised based on access options.
Whereabouts are you as once stripped I could sort this for you?

 

The break looks clean and fresh. This would lead me to think of two possible causes,
1, was the hole clean and dry BEFORE you put the stud in? If not this would hydraulically pressurise the tapped hole blowing the casting.
2, The stud is short or not bottomed in the hole and so overloaded the top few threads.

Liquid metal repair would be a poor option here especially with the fluctuations in temperature.
TIG welding is the only real option. The head will need removing and then a plan devised based on access options.
Whereabouts are you as Once stripped I could sort this for you?

 

http://www.allmetalweldingservices.co.uk/MobileOnsiteMotorcycleWeldingRepairs.html

Just found this I dont know them.

https://www.youtube.com/results?search_query=aluminum+engine+casing+welding

 

I can weld ....sort of
But I always get somebody else to weld aluminium for me

 

I would certainly not risk drilling it deeper!

The area needs building up first either with or without a hole.
A new tapped hole would be easily formed afterwards.

 

I’m with Eldon.

Strip her down, build up with tig, dress off, drill and tap.

 

Makes sense - the solution and the English!

 

Hope it works mate