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.
https://i.imgur.com/maWuk86.jpg
https://i.imgur.com/oR4ovEu.jpg
https://i.imgur.com/ZituYyr.jpg

I always get out the flame saw. (Torch)

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That'd be nice but sadly I don't have one and it's not in the budget right now :dance:

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 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.

You could try using another bolt to force it through

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 :D

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.

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. :D


That all is assuming they are studs and not threaded in there.

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 :cheers:

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!)

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.

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!

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