[Astro4x4]

The trick is as Craft59 said, start with a small bit, low RPM, work up in bit sizes, then I would heat that baby up and use an ez-out. Wish I was closer to ya man, good luck.

[The CyberPoet]

At this point, I'd completely drill and retap (or drill & install a KeenSert) -- probably the only options left. The only question there is whether it's feasible to drill a good replacement hole on the bike or if engine-out/drill-press will do any better.

Cheers,
=-= The CyberPoet

[gr8hntr]

just becareful using an easy out cause if its breaks off inside the bolt.. they are almost impossible to drill out.... they are very very hard

good luck

[cole449]

Sorry to hear of your trouble. I had the same thing happen with 2 of mine last spring. 1 came out when we welded on it. The other I had to drill, like was mentioned, starting at 1/8th and working up. I retapped 1 size larger to make sure i had good thread.

Good luck.

[DoubleD]

Number of header bolts that came out easily - 7 out of 8
New Diamond Cutting wheel for Dremmel Tool - $3
Dremmel pen extension - $45
Can of Liquid Wrench - $5
Set of Square extractors - $55
Set of Easy-Out Extractors - $50
New pair of kick-ass Vice Grips - $25
Bike stand - $125
Heater for garage - $35
House call by welder to weld a nut onto bolt - FREE (but didn't work)
Various titatinium bits and new set of Cobalt Bits - $75
Tap & Die Set - $60
Bottle of cutting oil/lubricant - $12
New bolts & gaskets - $25
Can of high-temp manifold paint - $5
Total number of tools borrowed - 6
Number of broken light bulbs from dropping shop light - 4
Number of WEEKS at this: 8

Having no surface rust on my headers? PRICELESS.

FINALLY got it done today. Tapped it out, picked up some new 8mm bolts, and started it up about an hour ago. I learned a lot, and have a lot of nice new tools out of this. My own advice/recommendations

to anyone out there who runs into this - do NOT piss around with Titanium-coated bits. Spend the money and get yourself a set of Cobalt ones. And don't waste your time or money on the Easy-outs. I read

other people comments saying this and should have heeded their advice. Just when I thought I was 'there' the Easy-out broke off inside the bolt and I ended up having to drill IT out.

Number of CC n Cokes I'm having tonight? Don't know - but I ain't counting them that's for sure. :P

[kwebbel]

TIP!
First thing I allways do with a bike is get those bolts out and replace them with thread-ends and nuts using a little cupper-grease, in my experience either one off the two ,thread-end or nut, will allways come loose.

[Range]

OMG...I just saw this thread!

In the future...PM me, I would have been over there in a flash.

I know it is too late now, but keep that in mind for the future.

(I rarely look in the Mechanics 101 forum because I don't have a Kat, and my input is not as valuable as some of the members on here)

[DoubleD]

Thanks Range - no worries. I pity the next stuck/broken bolt I run into!!