Broken Exhuast Stud

[He Man]

Got it out, but my new hole is slightly off center, not by much and not enough to affect anything serious. Its unforunate but that bolt really was completely fused in. Even after i cored the bulk of the bolt out, i tried to use heat and an EZ out to get the husk of the bolt out. that did not work so I have to basically drill out the whole thing. Sucks but the job is done!

[koko64]

It's an ordeal for sure.

[Howie]

Good to hear

[He Man]

Sent my frame off to powder coater. Frame is toasted at a joint. Its incredible difficult to repair at a joint like this since it is a node for 3 members. Im guessing water ingestion from all the salt water winter riding took its toll. Likely the actual section loss is in other areas as well. Sucks Now on the hunt for a new frame.

[Duck-Stew]

Fuhhhh...

Never seen damage like that before.

Good luck on the frame hunt!

[Howie]

Good thing you spotted that. 

[He Man]

Howie, I know! If I didnt send it off to the blaster, I would have ridden this until the frame quite literally snapped!

I suspect the following happened:

This is on the rear left engine mount. Water likely got in from the tail chop and sat on the joint when bike was parked...outdoors. This bike has been ridden in all weather conditions and likely salt water sat on the joint during parking and slowly eroded away after 19 years.

I would need to break out a UT thickness gauge to do a thorough spot check to feel comfortable on any repairs but I think its time to retire this frame as it's life has been harsh.  2 street crashes, 1 track day crash and was backed up into dozens of times + years of NYC outdoor riding.

I found a clean frame on eBay that Im trying to purchase and keep the project going, but part of me feels really sad that its not the same frame/vin.

The only thing original to my monster once complete will be the swingarm