Topic: Cross threaded one stud to header — advice?

[gmoss]

Repainted exhaust and repacked the baffle, cross threaded the very last nut I went to install.

Any advice on the best route to deal with this?

[MauiK3]

Remove the stud and replace it.
You can either use a stud puller, or double nut the stud after chasing the thread a bit.

[gmoss]

well i guess that's obvious enough, not sure what I was expecting. thx.

[rotortiller]

You could try chasing the threads with a die. Is it possible when the exhaust seats and is pulled in good threads will be engaged into the nut?

[Prospect]

It would be next to impossible to put a die on it with the stud still in there. There's just not enough room. Pull it out using the double nut method and then run and die on it. It doesn't look that bad.

[rotortiller]

If it were me I'd remove the exhaust to gain access with a die or thread chaser (provided the situation suggests it can be saved) then use the best method to rotate the die with what I had on hand. It is best to remain positive and try the easy approach first before pulling the stud due to risk in snapping it off, in that case you will have a real access issue. The exhaust has to come off anyway.

[Don R]

 Vise grips if you can't get two nuts on it.

[Hoosier Honda]

Could try a thread file with the exhaust off and out of the way, might clean it up enough to double nut it. I believe the pitch is 1.25.
https://www.amazon.com/CTA-Tools-8231-Metric-Restoring/dp/B00M9FZEQO/ref=sr_1_6?crid=3MKKWR0RYQT81&keywords=metric+thread+file&qid=1641261100&sprefix=metric+thread+file%2Caps%2C81&sr=8-6