At a loss trying to remove exhaust bolts

[Qingdao]

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

[itsnotanova]

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.

[Qingdao]

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.

[steved0x]

Originally Posted by itsnotanova

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

[Brian in Tucson]

Originally Posted by Qingdao

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!)

[husker boxster]

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.