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Everything is soft compared to carbide. I take it that you are replacing splined studs with through bolts during this process? Sounds like you're talking about the joint between the cats and mufflers?
I haven't pulled the exhaust of my Boxster (yet). So I don't know what lies beneath. If I were running into the same situation, I would consult Uncle McMaster (McMaster.com) and look at the drill bits I want, along with high temp anti seize and new hardware. I buy almost all of my hardware from McMaster, unless it's a need-it-today situation.
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