Big trouble-Advice on header removal

[Ryce Stallings]

While working on my endless project car I noticed that the mild steel header had rusted through and needed replacement. I wire brushed the stud and sprayed it with WD 40. When I went to remove the nut the stud sheared off. I stopped at that point and want to know the following from someone who has already gone through this misery what to do?

1. Cut the nuts off, remove the rusted header and then deal with the remainder of the studs?

2. Heat the studs up and try to remove the nuts again?

3. Any better idea?

Obviously I don't really want to drop the engine and do this the correct way!

Any one have some 1 5/8" stainless headers for an SC you want to sell?

[BlueSideUp]

There are some really good threads on exhaust removal. It's probably best to search "exhaust stud removal".

Generally you need to use a penetration oil like PB blaster on the nuts for a couple of days. Then heat up the nuts with an oxy-acetylene torch and slowly remove them.

If you bust more studs then you can try out the special tool developed by John Walker and another Pelican (Sorry I can't remember the name!)

edit:

I found some great threads....

Does anyone sell a fixture for drilling broken exhaust studs

Dreaded exhaust stud removal--heating the head

Anyone rent the jig for drilling out broken exhaust studs (3.2)

[Ryce Stallings]

Just what I needed. First I'm going to heat the rest of the nuts way hot right after they soak in PB Blaster a few days.

I already sent an email about the tool mentioned.

Will it hurt to drive the car with one stud missing?

[Mo_Gearhead]

QUOTE: "Will it hurt to drive the car with one stud missing?"
_____________

Short term ...No.

Over time, it will let the exhaust blow out the gasket (noise).