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**Jimbob181** · #1 23 Jul 2020

Hi all.
I’m in the process of rebuilding my 2003 XT600e which had to be stripped down as the exhaust headers had rotted and then welded themselves into the head.

Well on the way now, but I need some info before I machine the old stubs out of the head.

Can some kind soul provide me with the dimensions of the exhaust port that the manifolds plug into?
I need the depth to the copper washer, and any dimensions of the bore diameters before I attack it with the mill.

Many thanks.
Jim in Kent, UK.

**Grant Johnson** · #2 25 Jul 2020

Whew! Braver than me - I'd be terrified to go at it with a mill. After getting the steel exhaust metal down to flush on the head, I'd use a hand grinder, make a notch down to the ally, a small chisel (very carefully) to lift/pry up the steel and grab with a pair of vise-grips and try to peel it out.

Good luck, and let's see a picture!

**Mezo** · #3 25 Jul 2020

Quote:

Originally Posted by Grant Johnson

Whew! Braver than me - I'd be terrified to go at it with a mill

That`s what i was thinking, using a mill is unnecessary in my opinion, i SUGGESTED heat & some persuasion.

Mezo.

**Jimbob181** · #4 25 Jul 2020

Well I have to say that the mill was a total success. I had lots of control and just carefully machined away the steel almost to the alloy at 4 opposing positions. Quick smack with a hammer to distort the collar and it came out easily.
The copper washers were split with a smaller end mill and then could easily be prised out.
One of the studs had previously snapped so I replaced them all with M8 to M6 repair studs. Again, I machined the old studs out and drilled for the replacements using the mill.

If anyone is interested, the ports and studs are at 8 degrees down from the horizontal.

I’d post some photos but don’t know how to get them on a url.
J

**Grant Johnson** · #5 25 Jul 2020

Kudos to the wizard with the mill!

Re pictures, just click the paper clip to “attach” images and upload them directly.

**Grant Johnson** · #6 25 Jul 2020

Note to attach pictures you need to “post reply” and not use the quick reply. If you do quick reply click “go advanced” to get the attach option.

**Jimbob181** · #7 26 Jul 2020

Here’s a couple of photos of the before and after.
I’ve replaced all the studs too.
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