Stuck Exhaust bolt/nut - how should I proceed?

[drummr8]

So, I am removing the exhaust to get to the driveshaft and do the guibo and CSB, along with diff bushings. I got hung up at the exhaust though, since it is rusted to sh!t. I got 3 of the bolts/nuts out safely, but one of them rounded and is stuck. I already attempted to cut it in the tiny amount of space that I have, but I don't think it's going well. I've wasted quite a bit of time on this and I'm pretty frustrated at this point. What are my options? See pics below.

I may try my craftsman multi-tool, I believe there is a metal cutting blade in there that you can adjust to any angle and it should work in the small space. (I hope). IF I am able to find another tool to fit in there, what is the best way to go about cutting this? ie. what angle should I take, and what should I actually attempt to cut? I was attempting to cut the nut off of the stud, but that didn't seem to be working too well...

Also, YES, I used PB and also tried heat. Neither worked. I have terrible luck with rust.

http://img.photobucket.com/albums/v221/drummr6/image_zps4f635c2c.jpg (http://smg.photobucket.com/user/drummr6/media/image_zps4f635c2c.jpg.html)

http://img.photobucket.com/albums/v221/drummr6/image_1_zps2b44023b.jpg (http://smg.photobucket.com/user/drummr6/media/image_1_zps2b44023b.jpg.html)

http://img.photobucket.com/albums/v221/drummr6/image_2_zps58b8c3a6.jpg (http://smg.photobucket.com/user/drummr6/media/image_2_zps58b8c3a6.jpg.html)

http://img.photobucket.com/albums/v221/drummr6/image_5_zps26a6409d.jpg (http://smg.photobucket.com/user/drummr6/media/image_5_zps26a6409d.jpg.html)

http://img.photobucket.com/albums/v221/drummr6/image_4_zps66386feb.jpg (http://smg.photobucket.com/user/drummr6/media/image_4_zps66386feb.jpg.html)

Thanks for any input!

[ryankokesh]

Any way to drill it out with a drill bit? Flexible driver kinda deal maybe? :dunno


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[danewilson77]

Most likely will need to be cut out. Do you have all of the replacement brackets and nut/bolts?

"No flamesuit required"

[drummr8]

Any way to drill it out with a drill bit? Flexible driver kinda deal maybe? :dunno


Sent from my iPhone
I don't think it's possible to get a drill up in there :(


Most likely will need to be cut out. Do you have all of the replacement brackets and nut/bolts?

"No flamesuit required"

I have the bracket, need to pick up the gaskets and bolts/nuts. Any suggestions on how exactly to cut it? should I cut flush with the base of the nut (radially cut the bolt)? continue trying to cut the nut in half axially?? Cut the bolt in half axially? I don't know what to try next haha

[Vas]

Break it off and remove the exhaust. Then cut the stud flat with the flange and drill out the stud.

[drummr8]

Break it off and remove the exhaust. Then cut the stud flat with the flange and drill out the stud.

sounds so simple lol

There actually isnt a stud though. On the opposite side, there is an etorx (which is also stripped to hell because it was rusted to a nasty looking nub)

Hopefully if I cut the the bolt flush with the flange, I can just punch it out after heating the flange? (of course while being mindful of the O2 sensor)

EDIT: The car has a Borla exhaust, so I'm guessing when that was installed, the stud was damaged and replaced with a bolt? How many studs are there supposed to be? I think three of my connections were bolts/nuts, and one is a stud.

[Vas]

The factory exhaust has 4 studs pressed into the flange. Then there are 4 nuts on the other side. When I was removing my exhaust, all 4 nuts broke off as soon as I tried to remove them. So I ended up drilling the rest of the studs out and beating them out of the flanges. Then replaced them with stainless steel hardware ( bolts and nuts ).

[danewilson77]

The factory exhaust has 4 studs pressed into the flange. Then there are 4 nuts on the other side. When I was removing my exhaust, all 4 nuts broke off as soon as I tried to remove them. So I ended up drilling the rest of the studs out and beating them out of the flanges. Then replaced them with stainless steel hardware ( bolts and nuts ).
This is most likely the way I would go.

"No flamesuit required"

[Hornung418]

The new part offered by BMW is $22.00 per unit! Get a whole set and you'll never have to worry about it again. Heat the flange up til it's glowing. Then strike while the iron is hot so to speak and the bolt should come free.

Getting the bolt off should be cake with a sawzall.

[Vas]

Justin what new part?

[Hornung418]

http://www.ecstuning.com/ES26052/

They changed the part number for the press fit exhaust stud. The link above is the current part no. It's not on the car if you haven't replaced them yet.

[Vas]

I would still just use stainless steel bolts and nuts instead of that.

[Hornung418]

I would still just use stainless steel bolts and nuts instead of that.
My experience with SS bolts with SS nuts has not been good so far. Make sure they are re-torqued after a couple heat cycles. And make sure there is a thread locking technique applied so they won't back out. Or just use the stock copper locking nuts on the stainless bolts.