Any tips on removing old and rusted exhaust nuts?

[adamvfr]

I'm attempting to remove the front downpipes from my NC30 and not looking forward to it!

I've drenched the nuts with Plusgas for the last couple of days and attempted to remove the first one.
It didn't exactly go to plan and sheared off! I would say about 20mm is still poking out so I should be able to get some mole grips on it. Had a look at the nut and it looks rusted good and proper on the stud! I'm guessing the front downpipes have never been removed.

So, does anyone have any tips on removing the other 3? I'm sure people have gone through this process.
Would blow torching the nut help? Anything to help me extract them out would be great. I will be needing to replace the studs as well so this doesn't happen to me again!

Cheers,
Adam

[petrolhead19]

bolt extractors work a treat
and replace them with aluminium bolts :D
always works for me if im a bit stuck lol

Adam

[adamvfr]

Gotta a link to these bolt extractors?

I've got easy outs but there's no way in hell I'm using it on the broken stud. The last thing I want is to break one of them inside the head!

[hunter]

get someone to weld a nut one the remains of the stud,let it cool slightly then put a socket on it works everytime for me,when you know how many studs and nuts you want order the correct one's from rick oliver he is a member here,do not use aluminium bolts, they are far to soft.

[petrolhead19]

http://www.sourcingmap.com/pcs-damaged- ... =ukfroogle

bolt extractors easy to use, obviously you can get all different sizes, pick them up for about a quid from your local hardware store :D, hope this helps.

Adam

[adamvfr]

Yeah I do have a set of these bolt extractors though I wasn't too keen to use them as many people have said they snap.

Also don't have access to a welder or know anyone that does unfortunately.

I will try and remove the stud at a later date though first is to remove the three rusted nuts!

[Neosophist]

There good on larger nuts but for really rusted small stuff they can snap easy.

I had a sheared off exhaust nut that was sticking out.

Plus gas'd the hell out of it, then i blowtorched the surrounding metal to exand it and using an electric drill clamped the stub in the chuck of the drill as tight as I could.

Using a high-torque / slow setting I gently unscrewed the stud :)

Might be worth a shot

[adamvfr]

Definitely worth a shot! I removed a sheared disc bolt by drilling a hole in the centre and hammering in a torq bit, so I might try that as well.

Back to the the remaining nuts, do you think I should just dremel them off and extract the stubs in this manor as they will need all replacing anyway? Also read about nut splitters though I need the right size for the job.

I will be happy bunny after they are all replaced!

[NGneer]

I would just use lots of WD40 (or whatever your poison is) and very steady aplication of twist to the nuts to give them chance to break free before anything snaps. If they are rusted up solid, as they often are, all you will find is that they will bring the studs out with them, so no problem.

[adamvfr]

Well I cracked on with it today. One came out with the stud, another without the stud and third sheared again!
So one side has a stud and no stud. The other side has two sheared studs with about 15mm showing.

I've removed the clamps which hold the downpipes to the rear section though they are no budging for anything.
I've tried rubber hammering them, plus gassing them and using a propane torch!

Anyone had problems separating the pipes before?