Hi Jeff,
this van is sure supplying some real character-building experience for you -
lol !

you tried to wedge the flange off with a thin tapered chisel  ?
seems it would still be welded/corroded to the studs in the heads, or just
badly corroded to the head.
Don't want to damage the head flange surface though.

at least it's 'just metal'.

glad you're saving one of these fine machines !
Scott
www.turbovans.com

----- Original Message -----
From: "J Stewart" <fonman4277@COMCAST.NET>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Saturday, July 17, 2010 4:13 PM
Subject: Rusted Exhaust

Nothing more fun than working under a vehicle in 95 degree heat, but I
couldn't ignore my rusty exhaust any longer. I posted here a week or so ago
that I was pretty sure the nuts were going to snap off, I wish I had been
that lucky! Upon closer inspection, the pipes were rusted through were the
pipe meets the flange that bolts to the head , and not the first time
apparently. The is a receipt from the PO for "welding exhaust" and weld it
they did-nuts and all right to the studs, making it impossible to get a
socket or wrench on them (this is the front pipe, BTW) The pipes had rusted
through again, to the point were I was able to (after cutting through the
pipe) just twist it off, leaving just the flange stuck to the head. Then
using a Dremel (I love that tool, I'll never be without one) I was able to
grind the welded nuts/studs down the flange, at this point the flange should
have come off, but it won't, it is still stuck to the head. I can't figure
out why just yet, and after hours of working in the heat I had to call it a
day. Jeff

Jeff Stewart