Whats the condition of your exhaust headers? If its anything less than
awesome....I'd say cut through the weld, cut through the flange, and grind
away whatever you need too to get access to the stud. Then, after liberal
applications of penetrating oils, sufficient heat, and a GOOD grip on the
stud, turn it out and replace it.

As someone who had a mechanic break off a drill bit inside my head (engine
head, and at least in the bill.....my own head), the exhaust system (Pipes)
is far cheaper and easier to replace then the actual head. You get one
chance, take EVERY precaution, and do it right. I hate when this
happens.....

I can't even believe someone would do that. There is no logical reason to do
that other than you ran out of 10 cent nuts, or you had a chronic problem
with them loosening because you suck as a mechanic so much, that you had to
WELD it on.

-Craig
'85GL turned WESTY
Turned BOSTIG

On Sun, Jun 28, 2009 at 2:05 PM, David Beierl <dbeierl@attglobal.net> wrote:

> At 04:39 PM 6/28/2009, Jeff Hartman wrote:
>
>> disintegrate leaving the harder stud in tact, nice shiny welds around the
>> perimeter of the stud appeared directly welding it to the exhaust flange
>> and
>> bracket for the heat shield.
>>
>
> My first thought is use Dremel cutoff wheel (with right-angle adapter
> or flex-drive?) to cut the studs off flush and remove the
> exhaust.  Then weld or braze a nut to them so you can turn them out.
>
> Not much fun.
>
>
>
>  --
> David Beierl - Providence RI USA -- http://pws.prserv.net/synergy/Vanagon/
> '89 Po' White Star "Scamp"
>