For those of you who replaced your rusty exhaust flange studs...

[Traco]

I replaced all 6 last spring but mine is a Euro car so. It sure if it’s different.

On the OEM set up the bolts are actually splined studs press for into the cat side of the flange and the nuts are on the header side.

If something has been welded it sounds like someone has carried out some sort of quick fix at some stage as opposed to doing it the right and hard way.

I had to cut, grind, air hammer and use a press to complete the job.

Few pics for ref if it helps.









Detailed thread on Porsche club ireland forum below. The IT guys have been upgrading the hosting so I guess that’s why the IP address is there and not the regular URL but google should find it in the Boxster section of Porsche Ckub Ireland Forum

http://173.249.44.54/forum/index.php?topic=8501.0


This years job is to replace the ones attaching headers to the block - fun times ahead.


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[particlewave]

Originally Posted by Traco

If something has been welded it sounds like someone has carried out some sort of quick fix at some stage as opposed to doing it the right and hard way.

Incorrect. One of the nuts is captive and it's carrier is welded to the flange.

Originally Posted by Dave80GTSi

I am puzzled.

If the bolt which goes thru the welded top nut is already out, then why do you need to remove this rusty nut now?

Why not simply run a tap thru this old nut, thus recutting the threads, and then just use a new bolt?

Because it takes only a few seconds to cut it off and you don't want to reuse a rusted fastener, new threads or not. It will quickly rust again.

[Traco]

Originally Posted by particlewave

Incorrect. One of the nuts is captive and it's carrier is welded to the flange.

Are you saying a nut like this in the pic below?



If so then how do you screw a splined stud into that? This is the 6 splined studs that I took out of mine and there was no evidence of any captive nut on the header flange?



These had to be pressed out with a vice after a lot of heat.




As I said in my first post mine is a Euro S and the US has a different exhaust layout so maybe it’s different but I know what I took apart.


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[particlewave]

Originally Posted by Traco

Are you saying a nut like this in the pic below?



If so then how do you screw a splined stud into that? This is the 6 splined studs that I took out of mine and there was no evidence of any captive nut on the header

Yes, similar to that. It's been a while since I had mine off, but I believe two bolts on each side were splined studs and the third was a standard bolt with captive nut. A real PITA.

I replaced all of mine with SS bolts and nuts.