Hi chaps,

I have this:



I've marked where the threads used to be that mount to the bracket. (This is for a DT175C BTW.) Obviously someone previously sheared off the bolt ends when dismantling the bike and I'm just wondering what the easiest way of fixing it might be.

I could flatten off the remnants, drill and tap threads and then attach to the bracket with bolts instead of nuts. Or maybe there's not enough metal there and instead just cut the posts off and replace them with long bolts.

The unit seems quite solid - just surface rust - but a massive amount of rust fell out of it when I gave it a shake. It's not one where the baffle unscrews so if I had to get to the internals I'd have to resort to an angle-grinder. Maybe an after market exhaust would be better? If anyone has any suggestions...

I would heat and quench a couple of times, and then place a thin nut over the remaining thread and mig weld. They should come out easily.