Rounded exhaust bolts ( dump pipe )

[Limmy]

Hi Guys

Got a question. I had epic fail time trying to remove exhaust bolts underneath the car. I managed to round off one nut .

How can i get his nut off ? I have 3 to remove altogether . I tried spraying with CRC . no luck. none of these nuts are budging

[healy]

You could crc , blow torch to heat them don't use a shifter on them if that's how you rounded it use a spanner or socket set. Are you planning on puting the exhaust back on??

[Limmy]

yeah i was using socket . but it slipped. blow torch i see. i was at the Sunday market today , Guy was demonstrating a blow torch with those gas cans . Should've got one ! . also would a heat gun work ??
i'm trying to remove the dump pipe so i can get the egt gauge bung welded on.

[healy]

I'm not sure if heat gun will work it might let me know if it does heat does work well on stuck nuts and bolts etc best advice is just keep going at it you'll get it eventually

[NP99]

Try using a 6 hex socket, did you use a 12 hex? Also apply some butane heat as you discovered already.

[Sir Roofy]

Spray them again then again before you quit for the night
let the crc wd40 soak in over night

[hershal]

gas axe... works a treat with those stubborn bolts

[TPC]

You could try a Metrinch socket, can work with rounded bolts.
http://www.metrinch-tools.com/

[BillsGU]

Failing all that - go to a good tool shop and buy a nut cracker. They simply attatch to the nut and split it in half.

http://www.tooldesk.com/automotive/KDT710-KD-Tool-Nutcracker-NutBuster-Nut-Splitter.aspx

[kevin07]

you are talking about the bolts at the bottom of the dump pipe if so just cut them grinder or gas axe will do if at the top behind the turbo belt a socket on if that fails it is a removable stud so it can be cut

[NP99]

You could try a Metrinch socket, can work with rounded bolts.
http://www.metrinch-tools.com/

These are available at Masters - good value.

[Limmy]

Yeah was gonna grind off last option. Bottom bolt of dump pipe

[threedogs]

Maybe an air grinder will fit in confined area better, come in 90 or 180 degree.
thinking the 75mm one, or smaller.
I'd be replacing with brass bolts if possible like the old days,never had this problem
back then.

Have you tried a basin spanner??

[Tank]

Another good option to apply heat if you don't have a gas set is to hit it with an arc rod

[Limmy]

yeah will be tryin heat. my mate going to lend me his blow torch .

SILLY QUESTION : If i heat it . then use CRC ... SHOULD i heat it again or will it be flammable ?

[Limmy]

Maybe an air grinder will fit in confined area better, come in 90 or 180 degree.
thinking the 75mm one, or smaller.
I'd be replacing with brass bolts if possible like the old days,never had this problem
back then.

Have you tried a basin spanner??

Those big ones that plumbers use ?

[healy]

It won't go up in flames mate I always use crc and blow torch just have a spray bottle if water or something to get the water where you want it just in case. safety always comes first mate

[Limmy]

Thanks mate

[daves]

if you have enough room weld another nut to the rounded one and undo while its still on the hot side

[MudRunnerTD]

If you going to buy special tools to get these things off then seriously think about just taking it to an exhaust joint who specialise in taking those particular nuts and bolt off and get them to do it and weld the bung on and refit the dump.

It will be done and maybe not that much more and allot less stressful.

[Limmy]

Ended getting the rounded nut off . Thanks for advice guys .

I ended up trying .
- CRC spray
- Heat from blow torch
- use a 6 sided socket , instead of the star one which rounded it
- Also used my leg for strength

BUT...#*$!.... i ended up snapping the "bolt" that goes through the dump pipe bracket to the block . I'm having the worst time drilling it out . I snapped plenty of drill bits. I think it will take a lot of time and patience.
IM HAVING THE BEST LUCK !!!
So far i've tried
Drilling fast
Drilling slow
using COBALT drill bit now . I still haven't drilled in far enough for EASY-OUT to go in yet . I've ordered left handed drill bit on ebay . any experinced my problem ? Does anyone know how LONG this bolt is ? i'm drilled in about 5 mm

http://i97.photobucket.com/albums/l203/neegas007/20804373-9c61-4f27-9ffc-991d2a335ce7.jpg

[happygu]

Limmy ,

Bolt is only about 12mm thread length

Mic

[happygu]

Check the depth of the hole beside it for reference

[Limmy]

It looks similar to the bolt on the heat shield. Which is bout 12mm.

[happygu]

Limmy,

I only just took it off to install the Beaudesert Exhaust system, which came with its own bolt for the dump pipe mounting bracket, as it is a lot thicker.

I have the original bolt, but it is in a box with all the other bolts, but I seem to recall around 12 mm sticking out of the bracket ( It came from Beaudesert, with the bolt taped in the hole so it can't be too long, otherwise it would easily get damaged in transit.

Mic

[Limmy]

cool awesome thanks . I still haven't drilled through the bolt . I will definately give it a good go tommorrow when i knock off work. I ended up cable tieing the trigger of my drill so it holds the slow rpm drill. i still managed to break my cobalt drill bits.

[NP99]

cool awesome thanks . I still haven't drilled through the bolt . I will definately give it a good go tommorrow when i knock off work. I ended up cable tieing the trigger of my drill so it holds the slow rpm drill. i still managed to break my cobalt drill bits.

Careful that slow rpm don't kill/cook the drill.

[mudski]

Ended getting the rounded nut off . Thanks for advice guys .

I ended up trying .
- CRC spray
- Heat from blow torch
- use a 6 sided socket , instead of the star one which rounded it
- Also used my leg for strength

BUT...#*$!.... i ended up snapping the "bolt" that goes through the dump pipe bracket to the block . I'm having the worst time drilling it out . I snapped plenty of drill bits. I think it will take a lot of time and patience.
IM HAVING THE BEST LUCK !!!
So far i've tried
Drilling fast
Drilling slow
using COBALT drill bit now . I still haven't drilled in far enough for EASY-OUT to go in yet . I've ordered left handed drill bit on ebay . any experinced my problem ? Does anyone know how LONG this bolt is ? i'm drilled in about 5 mm

http://i97.photobucket.com/albums/l203/neegas007/20804373-9c61-4f27-9ffc-991d2a335ce7.jpg
What about welding a plate onto the dump pipe bracket and bolt up to the unused threaded hole to the right of the broken bolt?

[Limmy]

That is a good idea Mudski . if all fails , that will be an option

i used some high speed drill bits today and high speed. very good progress . i can see shavings . i'll buy some more of those bits as i snapped them. drilling slow didn't really work for me

[mudski]

Dip the drill bits in some oil so you don't blunt them so quickly and it will keep the heat down a little too. Would be quicker to weld a new plate I reckon. If you have a welder that is.

[pascal1]

you shouldn't be snapping so many drills, something is wrong, either you end up flexing them or let the heat goes up too much, what size of drill are you using?

[Limmy]

After a couple of weeks. HOURS AND HOURS . I finally got the bolt out !

Ended up using a hammer drill + bit of oil + easy out

I know people say do it very slowly. For me using hammer drill on max speed and thicker drill bits ( 1/8 from 5/64 ) and oil , this was most effective for me.

I'm so happy this is out now. Been having nightmares !! Thanks all for support and ideas !!

http://i97.photobucket.com/albums/l203/neegas007/20130617_161357-1.jpg
http://i97.photobucket.com/albums/l203/neegas007/20130617_161638-1.jpg
http://i97.photobucket.com/albums/l203/neegas007/20130617_162021-1.jpg
http://i97.photobucket.com/albums/l203/neegas007/20130617_162012-1.jpg

[Limmy]

pascal1, I didn't have any patience !! pushed really hard aswell !

[pascal1]

good job mate, you should frame the pics in your garage, I love the blisters!
about patience: did you quit somoking recently? (hihihi)

[Limmy]

I want to make a necklace with the bolr hahaha.

[menace 2]

Happy to see you had a final result ..but...you can't be serious mate ....16 drill bits and a couple of weeks !!!!...and a hammer drill ?/...stay away from my workshop !