Exhaust Hell

[Mike Andrew]

If there is a Hell, I will bespending eternity as a Midas or Meineke employee!
Spent several hours yesterday with a Dremel & carbide deburring cutter removing 2 bolts from the cat/ heat exchanger flange in an effort to replace a broken shield bracket. What a PITA! I literally had to machine the bolt shanks from the flange because they had corroded into place & couldn't be punched out after the nuts were ground off.
Due to access/ angle issues, I removed the caliper, rotor, heat/dust shield & removed the lower connection of the shock. What I had planned on taking an hour or 2 took me close to 6 hours, not including a trip to work to raid the tool crib for the deburring bits. Were I not so stubborn, I probably would have quit & taken it to my wrench where he would have used a double secret technique & had it done in 10 minutes.
Now back together & operational but what an ordeal.
Anybody got an easier method for future projects like removing the cat & inserting a bypass pipe?

[Nine9six]

Yeah Mike, but now the job is done! Hopefully you applied anti-sieze compound to the fasteners to reduce future frustration. There is no "easier way" on rusted fasteners. I give it one shot with penetrating oil, heat, and a wrench. If it strips, out comes the cut-off wheel. Been there, done that...

[Hugh R]

Try the Sears "Bolt-Out" sockets, as advertised on TV by Bob Viela. They're sockets with internal biting teeth, and they really work.

[john walker's workshop]

try a hot wrench next time. 2 minutes.

[Mike Andrew]

JW;

What is a hot wrench? Not familiar with this term.
Torch???

[john walker's workshop]

torch. just slice off the head of the bolt or nut when they're not wrench friendly.