KZ 650 Front Fork Pinch Bolt Stud - Help Please!

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The lowers we’re vapor blasted. It gives you an amazing satin finish. Finding a good blaster is key. Someone that can produce constant finish results even with jobs in different batches. 

Good to see some Vapor Blasting results.  I actually am seriously considering purchasing a good unit.  I have a KH500 Triple, maybe a H2 750, two Kaw 2 stroke dirt bikes, and this KZ 650 to further spiff.  This should justify the expense of the vapor blaster.  Already have my painter lined up.  Now to get dirty and make progress.  
Here is my KZ as it looks now.  Not so bad but could make cleaner 

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Vapour blasting should be done after sanding out the blemishes or the blemishes will still show after blasting.

I have a set of 650 forks that I don't intend to use.  Keep trying to get the stud out but know that you have a backup plan.  If you need them You can have them for the cost of shipping and a small donation to the site.  I live in BC, Canada.
 

Thank you for the very generous offer.  I will keep in mind.  And, thanks for the Vapor Blasting tip!  

Nice looking bike Forrest, also sounds like you are building an enviable collection 

Thank You Wookie!  I really like the bike.  Made me sick to my stomach when I snapped off the fork pinch bolt stud.  I will get it out.  It is bone stock except for CDI ignition, aftermarket shocks(Works Performance), and Race Tech fork springs.  The latter two changes really improved rideability and handling. 

Otherwise, I have a slight hoarding problem when it comes to motorcycles.  Other than the vintage Kawasakis and a couple of more modern ones(ZRX 1200R and C-14), I just purchase last fall a new KTM Duke 890 R.  I am sure there is a 12 Step Program but I refuse to be cured! 

 I am sure there is a 12 Step Program but I refuse to be cured!  

My name's Paul and I have a problem! 

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 I am sure there is a 12 Step Program but I refuse to be cured!  

My name's Paul and I have a problem! 

Now that’s damn funny i don’t care who ya are!

Just tell your lady that classic vehicles are a “blue chip” invest and don’t forget to hide the new ones at the back of the pack 

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wrote:

 I am sure there is a 12 Step Program but I refuse to be cured!  

My name's Paul and I have a problem! 

Now that’s damn funny i don’t care who ya are!

Does one of those 12 steps involve buying more motorcycles? If so I might be in that program already.

You guys are all just too funny.  

Now someone get over here and yank this stud outa my fork!  

Whelp,  over the weekend, I gathered extra bits and pieces to aid my effort.  I have removed the fork and inverted in an improvised set up.  I have a standard 3 1/2" vise that I have clamped a large heavy spring loaded clamp.  I have secured one of the handles of the spring loaded clamp in the vise.  The clamp extends out to hold the inverted fork.  I further protected the fork with some 1/8 - 1/4" thick urethane.  I also picked up a carpenters vise at Harbor Freight just in case.  I am now spraying penetrating oil direct onto the stud and applying heat with my hand held butane torch.  NO success yet.    Since, I was a bit of an idiot and tried to remove the broken stud with vise grips, the threads & shank have become stripped.  However, I have still been able to thread nuts over the damaged threads.  It got me to thinking that I might be able to extend the threads further down the stud with a die tool.  If successful, I could get get two nuts with a lock washer in between and see about turning out; the ole double nut tactic.  I hesitate to weld the nut to the broken stud until I exhaust other options like this.   I also went to the hardware store and got the barrel nut, allen adjuster bolt and a chrome ball bearing for the eventual install of new studs.  Thanks to Mikaw!  Will update with progress.  Wish me luck!

Sounds like a plan Forrest, good luck 

two nuts are better than one...!