Hey Aaron,

Two things that have always helped me with rusty bolts are a set of damaged
bolt removers and some PB Blaster.  Rust is quite common in my neck of the
woods so I've dealt with quite a bit of rusted exhausted.

The bolt removers are here -
http://www.sears.com/shc/s/p_10153_12605_00952060000P?keyword=bolt+out  They
are not too expensive and cover most of the sizes you'll need.  PB Blaster
can be found in most hardware and auto parts stores here.  If not, their
site is http://www.pbblaster.com/.  Thirdly, I like using vice grips to get
the studs out.  Sometimes the studs come out with the bolt but sometimes
they don't.  Removing rusted exhaust is never an easy job so patience should
be your friend.

Also, be careful using the plumber's torch.  Similarly to removing spark
plugs when the engine is warm, if you heat up the aluminum head, it is
possible to strip out the threads.

Andrew

On Mon, Jan 18, 2010 at 3:10 PM, Aaron <a.robinson.lists@gmail.com> wrote:

So my first questions in this undertaking are:
> What's the easiest way to remove a rusty exhaust (especially the studs in
> the heads)? Is there some special secret? Some tool that turns a helping of
> inept-ness with a few tools into success?
>
> I have a gently used exhaust, new gaskets and bolts waiting. I just need to
> figure out the easiest method of getting the old one out of the way. I have
> available: a plumber's torch, wrenches & sockets, hacksaw and a waning
> desire to not pay someone else to do it.
>
> Thanks!
> Aaron
> '87 westy (in WA with van from Illinois)