I'm going to have to recommend one of my favorite recent tool
acquisitions, the erwin removers that have a reverse spiral set of
teeth in them that you hammer onto a rounded/rusted bolt and then the
teeth bite more the harder the thing is backed out.

Don't be afraid to use heat to loosen nuts, a lot more effective than
penetrating oil. A good nutcracker works well, as does an angle
grinder. But a stud remover and don't mess with vise grips.

Jim

On Mon, Jan 18, 2010 at 7:29 PM, Aaron <a.robinson.lists@gmail.com> wrote:
> 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)
>>>
>