Rusty Bolts

[DRock9]

I am trying to put my Mac H-pipe on right now and i can get the ones connecting to the catback but the four header bolts are practically welded on because of the rust. It is my understanding that all the bolts on the exhaust are 5/8", i started off with that but it wouldnt grip the bolt, so I went to a 15mm and that wouldn't grip either. I went down to a 9/16" and 14mm but those wouldn't even really fit on. I've tried PB Blaster and let it soak overnight and it didn't help, I just tried torching it till it was cherry red and that didn't help. I was thinking about just cutting them in the middle and installing new ones but I wouldn't be able to get the part connected to the header flange out. Can anyone give me any insight on what to do with this? I am thinking of going to Sears and getting a "Gator Grip" socket and maybe some impact wrench sockets. Thanks!

 

[DRock9]

Can anyone help me out here? We all have 15+ year old cars and i'm sure almost everyone has had to deal with some sort of rust. Will I have to cut the bolt and re-drill and tap it?

EDIT: I'm thinking of just returning the mid pipe and get something else from 50resto instead.

 

[DRock9]

Well I just tried one more time and ended up snapping the bolt, what should I do? Do I have to drill and re-tap? I am thinking about just saying "**** it" and buying new headers...

EDIT: And if I buy new headers what is the power difference between equal-length and regulars? And is ceramic neccessary?

 

[DRock9]

So I just rounded off the socket, looks like i'm done. If I were to buy headers, how hard would it be for me to install them myself? The only job i've ever done on a car that is worth listing is changing my heater core in my fox, but thats not real technical just very labor intensive. I dont want to pay $150 when I can fork out another $40 and get headers and then install them myself, which then would make my H-pipe a piece of cake.

EDIT: I was thinking and it couldn't be that hard to install headers, just jack the motor up and slide them in and bolt 'em up. I don't think that I would hit any roadblocks like today, nothing could be rusted on could it?

 

[cdog301]

bolts

since you are going to sears anyway get a Craftsman screw extractor set drill the top and use the extractor you tap in with a hammer to ease out the bolt!

 

[jrichker]

I have had the H pipe on my car down several times. I don't personally know of a way to replace the headers without disconnecting them at the same place you are having problems with now.

As far as choice of headers, the FMS stainless steel headers are excellent fit, finish and quality. The uncoated ones I have are in excellent shape after almost 100 K miles and 5 years of daily driving.

 

[Snikt89GT]

Rusty bolts? Here is a good way to remove:

View attachment 421568

 

[DRock9]

Thanks for the replies, and Jr I plan on cutting the bolts with my torch to disconnect them both since they come with new ones any ways.

 

[dragnazz5.0]

if you end up cutting them off leave enough room to get a pair of vise grips on them. heat them up with a torch until they are red hot and than take an ordinary tea candle or whatever candle you can swipe from your mom or girlfriend and press it onto the stud making sure the wax gets down onto the threads. the wax will do the same thing that pb blaster does but ive found the wax method to work 10 times better. we had the same thing happen to us and the wax worked.

 

[Deleted member 87397]

I've honestly never met a bolt that PB Blaster could not take care of so I'm afraid I can't help much there, but if you end up with new headers you would have not trouble installing them. If you can change a heater core you can do headers. There's not much of a power diff between equal and unequal and the unequal are a little quicker to install. Good luck.

 

[HISSIN50]

I'd hit the fasteners again with PB. Then again. Then again when you go to remove them with CDog's great idea (I've had outstanding results with Bolt-outs).

The bolt-outs might either work, or allow the stud to fall apart (I got that lucky on the last snow-car I worked on) and either way, it should help.

Good luck.

 

[DRock9]

Thanks for all the replies, i'll ponder my course of action while i'm in school today. I'm not sure if PB will work since a torch didn't, I got them cherry red 4-5 times and there was no give. They are practically welded on from all the rust in the past 17 years, maybe ill try that candle thing.

 

[dragnazz5.0]

people think im stupid and give me wierd looks when i tell them about the candle trick. but ive used it multiple times and it has worked when pb blaster wouldnt work. the good thing about the candle wax is that you dont have to let it sit overnight like you do with pb blaster. you might not want to get the stud so hot that the wax evaporates as soon as it touches but hot enough so that the wax just runs freely down the stud and into the threads. hell even if you get new headers just try it out and see if it works

 

[DRock9]

Thanks a lot, if I dont like the price quote i'm going to get tomorrow i'm going to try the candle thing then if worse comes to worse make a decision on headers or paying for the install.

 

[DRock9]

I got a $50 quote, but once I got there he said he would have to replace all of the studs because there was no way he could reuse them so it would most likely be up at around $80-$100. I told him to cut it off right before the second set of cats so I kept the air line, and then he welded on a hanger because the old two were rotten off. He also took off my cat-back system because I told him I would be buying a new one soon, so now I am running with two cats and no mufflers or tailpipes and its wicked loud.

I love it.

EDIT: Does anyone know if it is illegal in MA? As far as the police officer knows, it only came with two cats and since I kept those two on it will still pass emissions so the only thing I can think of being illegal is the loudness of it. Ill go research some but I know harley's are just as loud. Thanks!