Need Help-I hurt my Harley

I recently broke-off (1) one of the threaded bolts that secures the voltage regulator to my bike.(2002 Road King Classic)
The base of the threaded bolt is welded to the frame of the bike. I have an idea or two of how I plan to fix this problem (and it won't be pretty) but would appreciate any advice I could get from anyone else who may have done this same stupid thing.
Thanks from Ontario, Canada

Just as with any other fastener that is welded to a fixed point, you need to remove, drill, place a new stud, weld and paint. That's the right method. You can get by with just removing the old stud by grinding off the old, drilling out the old, cutting threads into the mounting plate, and place a short "all thread" rod in it's place.

J.B. Weld.

Although J.B. Weld works for some things, in this application, do you think that intensive and possible heat will not be strong enough for J.B. Weld?

Why skimp!!?

Hmmm......$18,000.00 (+ or-) bike.....0.99 cents JB weld......doesn't pan out in my book. It's not that hard to simply replace the stud! If the JB weld doesn't cure properly, isn't mix right, or the surface isn't prepped right, the regulator can shift. The regulator itself isn't hard mounted making it succeptable to vibration. That's a CRUCIAL and significant piece of electrical hardware there..not to mention the potential damage that can occur if it grounds out! Then your'e spending big bucks replacing wiring / electrical components.

Remove the regulator and grind off the stud at the base. Center punch it and drill it out in steps to the same size hole 5/16'? I don't remember it being 3/8". Use a long enough bolt and washer to go through to the approximate same height as stock and I would top off with some acorn nuts and washers. Make sure the regulator surface is clean of rust as it is the ground for the regulator also.

Flying a bit blind here as am working from a remote location.

need help

I don't know where the mount is on a road king but , does the bolt go through the mounting plate? If goes through you might be able to drill the broken bolt and run it through the plate, and out the bottom of the bracket.
Just a guess.

Thanks for all your helpful suggestions.
I agree. The repair should be done half-assed right.
I was/am installing a chrome v. reg. cover so all I need is an identically threaded stud.
Can I remove the voltage reg. from its moorings without disconnecting any wiring in order to do the repairs without causing a short or something as bad??????
Komokaman

Disconnect the battery

Howdy,
Rule number One when doing any sort of electrical component work...Disconect the battery ground cable. Takes just a few minutes and can save your hands...it really hurts punching garage walls cause you fried your system........

electrical

Amen, brother