Well I shaved the axl holder down in that corner about 40% to accomodate the bolt. I wanted to get some type of hold in that corner instead of riding around with only 3 studs.
I figured it'd be better than nothing...

Here's another pic from more of a top angle.

 

That was ballzy of you to shave off the collar. Now you got two parts that you will need to replace later.

 

wow..

It's just a stud dude. hahaa.. I wouldn't trust that thing now!

 

Try to minimise how many times you screw something in and out of the fork leg.
It's soft an can easily be worn/stripped.
Then you have a problem
That is why studs are used and not just bolts.
So whether you get a proper stub or just cut down a bolt, do it once and leave it.

 

Ok, I see what you did. I first thought you cut off the whole corner not just shaved it down. Did you use a mill?

Tig/mig weld a nut onto the broken stud. That way your not having to heat up the whole fork leg bottom. Just concentrating the heat on the one part, and the locktite would be loosened up also. Like brewster said the xr stud is the right part, and I'd buy two one for a spare. Look it up on service honda, its gotta be cheap.

 

I bought 10 lol, just in case. RaceGass read his post he told you what he did

 

oops i just skipped to page two .. doh!

Great idea Mav quantity!

 

Plenty of spares although now I have a torque wrench I shouldn't break any more

 

Welding shouldn't be required.
A decent set of vice grips should be enough.
Even if you file a flat spot on the stud.

 

I'll try heating and a pair of vice grips. The stud is made of softer metal in the center where it broke, clearly a defective part. I hope it doesn't break when I'm trying to remove it.

Mike