Go Back   986 Forum - for Porsche Boxster & Cayman Owners > Porsche Boxster & Cayman Forums > Boxster General Discussions

Reply
 
LinkBack Thread Tools Display Modes
Old 03-18-2020, 12:06 PM   #1
Registered User
 
Aggromuffin's Avatar
 
Join Date: Oct 2017
Location: Santa Maria, CA
Posts: 52
At a loss trying to remove exhaust bolts

(2001 S) Hey guys, bought some exhaust parts off eBay and they came with a little surprise. The original bolts were cut on one end but they seem to be word welded on in the other end. And I can't reuse them because they're half size so I HAVE to remove them. I've searched on the forums and I've seen talks about just cutting the head off and they fall off but I've also seen talks of some bolts being pressed in. Here's what I have so far and what the other bolt that I haven't gotten around to yet looks like. What do I need to do? I've cut off the head and grinded the side down but I still can't hammer it out.




Aggromuffin is offline   Reply With Quote
Old 03-18-2020, 12:53 PM   #2
Who's askin'?
 
maytag's Avatar
 
Join Date: Mar 2018
Location: Utah
Posts: 2,214
I always get out the flame saw. (Torch)

Sent from my SM-G970U using Tapatalk
maytag is offline   Reply With Quote
Old 03-18-2020, 02:31 PM   #3
Registered User
 
Aggromuffin's Avatar
 
Join Date: Oct 2017
Location: Santa Maria, CA
Posts: 52
Quote:
Originally Posted by maytag View Post
I always get out the flame saw. (Torch)

Sent from my SM-G970U using Tapatalk
That'd be nice but sadly I don't have one and it's not in the budget right now
Aggromuffin is offline   Reply With Quote
Old 03-18-2020, 03:04 PM   #4
Motorist & Coffee Drinker
 
78F350's Avatar
 
Join Date: Jul 2014
Location: Oklahoma
Posts: 2,736
Garage
Grind off the rest of the bolt as short as possible, the re-drill the hole with either a titanium coated or cobalt drill bit. You may want to start with a small bit and work up in size.
__________________
I am not an attorney, mechanic, or member of the clergy. Following any advice given in my posts is done at your own peril.
78F350 is offline   Reply With Quote
Old 03-18-2020, 03:38 PM   #5
Registered User
 
Join Date: Oct 2016
Location: Houston, TX
Posts: 44
I just did this repair recently. I left the broken end protruding and put a socket on the other side then used my bench vise to compress the broken end into the socket. I just applied about 20lbs of force and heated w a run of the mill propane torch around the flange and within 20 seconds the bolt POPPED into the socket. Now that you’ve ground down the broken end flush you’ll need to find some scrap metal to force the remainder through.
__________________
2004 Boxster S 79K Miles
Htci is offline   Reply With Quote
Old 03-18-2020, 03:41 PM   #6
Registered User
 
Join Date: Oct 2016
Location: Houston, TX
Posts: 44
You could try using another bolt to force it through
__________________
2004 Boxster S 79K Miles
Htci is offline   Reply With Quote
Old 03-18-2020, 04:43 PM   #7
Registered User
 
Qingdao's Avatar
 
Join Date: Jul 2019
Location: Charleston
Posts: 309
Take the piece to an exhaust shop with cash in hand and get them to cut off that flange and weld on a new one.

Looks like you have enough area to drill another hole (not centered on the existing ones) and drill a subsequent hole on the other side of the flange. If that explanation makes any sense
__________________
'99 engineless Base boxster

Last edited by Qingdao; 03-18-2020 at 04:46 PM.
Qingdao is offline   Reply With Quote
Old 03-18-2020, 05:54 PM   #8
Registered User
 
Join Date: Jul 2013
Location: Bastrop, Tx
Posts: 2,451
Back when I use to sell boxster parts I would come across this problem a lot. A hammer and punch makes quick work of removing broken studs that are flush like yours. The one's with stubs usually come out with a quick hit of a hammer.
__________________
Woody
itsnotanova is offline   Reply With Quote
Old 03-18-2020, 05:58 PM   #9
Registered User
 
Qingdao's Avatar
 
Join Date: Jul 2019
Location: Charleston
Posts: 309
They are studs or bolts??

If they are studs put a socket on one end of the stud and use a C-clamp to push the stud out. Use a smaller socket on the other side of the C-clamp to push the stud out.


Or do what I'd do and air hammer the thing out.


That all is assuming they are studs and not threaded in there.
__________________
'99 engineless Base boxster
Qingdao is offline   Reply With Quote
Old 03-19-2020, 04:40 AM   #10
Registered User
 
steved0x's Avatar
 
Join Date: Dec 2012
Location: FL
Posts: 4,073
Quote:
Originally Posted by itsnotanova View Post
Back when I use to sell boxster parts I would come across this problem a lot. A hammer and punch makes quick work of removing broken studs that are flush like yours. The one's with stubs usually come out with a quick hit of a hammer.
Yeah, when I did my Cayman it was similar (but not quite as bad) and I used a tie rod press loaner tool from O'Reilly Auto parts to press them out, and the ones that didn't quite come all the way, a light tap with hammer and punch. Edit: only works if there is some of the stud sticking out. Since your parts are off, you can really support that flange, and a good whack with a hammer and punch
steved0x is offline   Reply With Quote
Old 03-19-2020, 02:45 PM   #11
Registered User
 
Join Date: Jul 2017
Location: Tucson AZ
Posts: 536
Quote:
Originally Posted by Qingdao View Post
Take the piece to an exhaust shop with cash in hand and get them to cut off that flange and weld on a new one.

Looks like you have enough area to drill another hole (not centered on the existing ones) and drill a subsequent hole on the other side of the flange. If that explanation makes any sense
Take it to Midas Muffler and let them work it out. Ain't worth the trouble for what they'll charge you. (I like my Midas men!)
__________________
2001 Boxster
2007 Toyota Highlander
2003 New Beetle Convertible, Turbo, Tip 6 speed
Brian in Tucson is offline   Reply With Quote
Old 03-20-2020, 12:36 PM   #12
Registered User
 
husker boxster's Avatar
 
Join Date: Sep 2006
Location: Omaha
Posts: 2,448
Just went thru this with my 928 (update to thread coming). I ground the nut end flush with a dremel. Next step was to take a hammer & punch to them. Thankfully they all came out with some healthy whacks. My next step was to use a yellow benzene torch on them. The blue version doesn't get hot enough, supposedly the yellow one does. A yellow version costs $50 at Lowe's.
__________________
PCA National HPDE Instructor
2008 Boxster S Limited Edition #005
2008 Cayman S Sport - Signal Green
1987 928 S4 - Granite Green Metallic (Felsengrun)
husker boxster is offline   Reply With Quote
Old 03-20-2020, 12:48 PM   #13
Registered User
 
Join Date: Jul 2016
Location: Ireland
Posts: 133
See my posts here. I think the stuff that will help starts around post 8

https://r.tapatalk.com/shareLink/topic?url=http%3A%2F%2F986Forum%2Ecom%2Fforums%2Fs howthread%2Ephp%3Ft%3D74097&share_tid=74097&share_fid=31135&share_type=t&link_source=app


Older but not any wiser!
__________________
Traco
_________________
Older but no wiser.
2003 Boxster S, Seal Grey
Traco is offline   Reply With Quote
Old 03-22-2020, 02:13 PM   #14
Certified Boxster Addict
 
Join Date: Nov 2010
Location: Los Angeles
Posts: 7,665
I heat it up using a $20 propane torch until its red hot and then hit it as hard as I can with a hammer and punch. Pop! And you're done.

I usually wind up in this situation when its still on the car so I'm struggling to avoid setting the underside of the car on fire. Should be a 5 min job on a workbench.

https://www.homedepot.com/p/Bernzomatic-WK2301-Propane-Torch-Kit-333084/202539561

__________________
1999 996 C2 - sold - bought back - sold for more
1997 Spec Boxster BSR #254
1979 911 SC
POC Licensed DE/TT Instructor

Last edited by thstone; 03-22-2020 at 02:18 PM.
thstone is offline   Reply With Quote
Reply


Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On




All times are GMT -8. The time now is 12:39 AM.


Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2020, vBulletin Solutions, Inc.
Content Relevant URLs by vBSEO 3.6.0
Copyright 2018 Pelican Parts, LLC - Posts may be archived for display on the Pelican Parts Website -    DMCA Registered Agent Contact Page