Topic: Broke exhaust mounting stud, what to do??

[lucky]

I would pull the head and had the stud EMD out.  EMD is the best way to deal with it - unless you have enough stud left to get it out by force.

I agree completely . Have a machinist deal with it. They deal with those all the time.

[Cb750k7.]

I would try cutting a flat head slot in what is left of the exposed bolt with a dremal, heating it up and use a flat head attachment for a socket wrench. Apply torque not to much where you would snap the bolt, keep the tension even for a minute or two and as the heat transfers from the bolt to the aluminum head and the metal reacts to it, it should loosen off.   

[BuffaloBill]

A MIG ( wire feed) welder really does work well.  Just use small tacs to build up enough material to grab with a vise grip.  Use a fairly high setting on the welder but brief tacs.  The aluminum surrounding the stud does not melt away like some might think.  Anyone proficient with this welder can do this. 

That's what I'd try before total disassembly.