05 S with 131,000 cared for miles by one owner. Went to replace a muffler hanger located in the rear on the passenger side. There are 2/ea, 8 mm ? (please confirm) studs coming through the boot that are attached to a 4" bracket, (see photos) The studs were rusted into nothing. This inside the boot bracket is spot welded into the boot but I was able to free it with no damage. Question; can anyone recommend a fix? I was going to repair the original boot bracket and fabricate new 8mm studs on it. Thought I would check here first if anyone had a personal solution they would like to enlighten me with.

Thanks in advance,

Buggy

underneath view of area showing 8mm studs and nuts

Inside the boot top view of bracket

Inside the boot angle with ruler

 

Could you redrill the holes and feed a bolt and nut through? Could use a rubber washer on the nut to prevent moisture from coming up .
could always look into possibly the universal hangers and attach them in a different location so long as the exhaust is supported.
but I coulda swore the exhaust brackets can be unbolted and replaced

 

I'm in the same boat man. Broke both of the rear studs off getting my brackets off so I could drop the rear heat shield. My plan is to drill out all 4 studs and replace with stainless, epoxy them in and then re-rubberized undercoat around them top and bottom. As for the brackets themselves - those suckers are pricey. I found one side for $35 from the Atlanta BMW/Mini place, the other side is like 75 bucks (stock must be low)! If you find another solution, I am interested in hearing it!

 

If it wasn't so dang cold out I colda tried getting some fir u guys from my local salvage yards..

 

Found the solution. Networked with a local car repair entrepreneur that sourced this part for me. With the two nuts it was $15.00.

 

Thanks for the follow up and solution - one more Q for you... are the sold singly or by the pair? Thanks!

 

I was able to purchase just the single unit.