Well I'm doing fairly well. 6 of 8 studs removed without too much trouble. Now I'm to the last 2. 1 is a full length stud that is mangled (I had to cut off the nut) and the other is about 1/2" leftover of the bolt that sheared off. My vice grips are of the "cheap" kind and don't seem to hold the studs well enough to turn them. So hopefully if I can source a better tool and will be home-free with no drilling needed.

I've moved on to the water pump until I figure out how to get the ast 2 studs out. Suggestions are appreciated.

This would be fun if I didn't have better things to do!
Aaron

On Jan 18, 2010, at 2:29 PM, Angus Gordon wrote:

> I'll add to what Andrew suggested - tapping. Find a socket you can fit with
> a hammer, then give it two minutes of tapping to loosen up the rust. I've
> removed unrecognizable rusted exhaust nuts/bolts this (slow) way with no
> damage.
> 
> 
> Angus Gordon
> Bainbridge Island WA
> 
> birdworks@gmail.com
> 
> 
> On Mon, Jan 18, 2010 at 1:46 PM, Andrew Philbrick <herrschildkrote@gmail.com
>> wrote:
> 
>> 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)
>>