Dansk premuffler install questions
 

Just started removing old cat for premuffler, and have 2 questions:
1. The heat shield is attached by brackets at both ends. Should I reinstall the shield with the Dansk premuffler?
2. M8 bolts are just blobs of rust. Whats the best way to get them out? I dremeled off one nut and tried to hammer the bolt out the other side and it would not budge. Then I cut off the stub of the bolt and tried hammering with a drift - still not move. Will I have to drill the bolt out? What kind of drill bits would I need for this?
(yes, I have drenched them in PB Blaster)
One more thing. I bought a new O2 sensor from out host and it does not have the rubber plug on the wire sheath. Isn't it supposed to have the plug? I know I can cut off the old plug and wedge it on, but it won't be as secure and the old plug is not in great condition. Last time I bought an O2 sensor it _did_ have the rubber plug.

Heat shield was for the catalytic converter. Toss it. Best way to get the old bolts out is with a torch. If you cut off the nut and it won't move with a drift, try a bigger hammer. If you drill, get titanium coated drill bits. Seems like my 02 sensor came with the rubber plug. I would call Pelican and check with them.

Re: Dansk premuffler install questions
 

1. No heat shield for the premuffler - take it off.
2. I cut the nut in half with a dremel on each one (yes cut every nut!) then used a wrench to get it off. After you get all the nuts off wiggle the whole exhaust to break the seals. That's the only way I was able to budge the last nut...
3. Yes, O2 sensor should have the rubber bung - call Pelican customer service.

PB Blaster is your friend...

Thanks for the replies. I called Pelican service and was told if the O2 sensor did not come with the rubber plug, then the vendor (Bosch) does not include the plug any more!

Hi John,

You might check this thread out for some installation tips;

http://forums.pelicanparts.com/porsche-911-technical-forum/152793-where-get-exhaust-installed.html

I know you're past this, but if you soak the nuts and bolts the night before, they do much better in coming out/off. The previous suggestions for removing the rusted nuts are right on. If you've hacked the nuts off and still can't get the bolts out, I'd soak them with PB and you should be able to tap them out with a punch, or something similar.