The latest in my saga of returning my 2005 R53 project to viable transport...

replacing the exhaust system (cat back) I twistEd off several bolts holding rear muffler hangers. Not too big a deal - a little Dremel and drilling work and new bolts hold the new mounts. But down at the join between the cat and the exhaust pipe where two really rusted bolts hold the pieces together, I was able the generate enough force to snap one of those. Didn’t think it was possible, but with a long enough lever, ...

I’ll be able to answer this soon enough, as I crawl back under there tomorrow or the next day with heat to apply to the surviving nut, but in the meantime, here’s my question. Are those two bolts welded on to the flange, or will they break free once heated to the temperature of the sun? On one video I watched, they spun freely. In my picture, I’m not sure. I think I see something surrounding the bolt head, but if it’s a weld bead, it’s a pretty crappy one. So what do you think from your experience? With some heat, can I turn that lower bolt and remove it from the flange? Not relishing the idea of drilling it out. At all.



Picture looking toward rear of car showing exhaust pipe flange with two bolts and pipe cutter in background.

 

Had a hack saw my bolts of last time. When I had to change my exhaust.

 

If you cut the nuts off. The studs will knock of the resonator. I order news ones for mine when I ordered my new exhaust. Something told me to order studs an nuts.

 

With some heat and quenching, I was able to remove the remaining nut. But I can’t get the flanges to separate. The side with the snapped nut comes free, but the side with the stud still in place is stuck tight. I’m worried about too much force damaging the cat converter flange or something else.
I guess I could try some heat somewhere. I think the bolts are brazed in place. Don’t know how to safely remove the broken one. I may have to get it trailered somewhere. It’s exceeding my capabilities.

 

Looks like ur close. Maybe get an extractor socket on it?

or a punch / wedge from the bottom up. Hammer it in between the flanges toward the center and on each side of the bolt...

sometimes taking a break and boing back in fresh helps...

 

https://www.harborfreight.com/air-im...kit-92037.html perhaps ?

 

Thanks to the tips here and the encouragement, I persevered and got the flange separated. It was a little more work than I bargained for, but I took that to be punishment for twisting off the bolt.
I used heat to get the flanges to part, and then hacksawed off the head of the snapped bolt. When the cut was about halfway through, I put the wrench on the bolt head, and it came easily loose and out. I’m thinking that they were not welded or brazed in place, and if I’d just used heat in the beginning, it all would have come apart in hours, not days.
When we did the “old age downsizing” thing a couple of years ago, I had to give up most of my tools - air compressor and welder among them - and just spent time and money replacing some of them. Primarily, jack and hand tools for this adventure. Attempting to restore my lost manhood, I guess, undertaking this project.
All that’s left now (for this subproject) is to bolt the new pieces together, raise them up, and secure the clamps.

 

good to hear!

what exhaust system are you putting in if I may ask?

 

I’m putting in an oem style Ansa brand system from carid. It was less expensive than the specialty ones, and probably quieter. It may not last as long, but seems pretty sturdy.

 

After thinking about the baby food jars, I said, “is this what the car deserves? No. “ and called up the Mini dealer. Real washers were $1.04 so I put them on. They’ll probably fall off. One of them wouldn’t even bite, but I feel better about them.