Removing exhaust studs. Risky?

[dsrtrat]

Doing my exhaust swao went ok in one direction but now i habe a problem with VnH flange being so bad that i cut it off and the stock two piecer not fitting with the VnH pipes.

I have two options. Make a custom two piece flange on my mill and paint it with high heat stuff. Or, i could try and remive the studs.

Option 2 scares the shite out of me. If had bolts snap off on sruff before and its not fun. Snapping one off in an aluminum head on my bike feela like a bad situtation. Ive even read where a fellow cracked his head doing it. Not a fix i want to deal with.

Anyone have the good, the bad and the ugly on this? I used wd40 to get exhaust off other bike and one of the stud did spin instead of the nut.