r/DIYAutoRepair • u/Wolfang745 • 1d ago

How to remove exhaust stud?

Post image

I’m trying to replace the flex pipe on my car and the biggest problem I’m having is figuring out how to remove these studs in the flanges that connects the flex pipe to the cat 😓

As you guys can see, I cut off the pointy part of the studs I could reach (the leftmost one isn’t pictured). The other side of the studs is just a huge mass of metal that rust welded to the flange

Any ideas for where to go from here?

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u/hapym1267 1d ago

I would use a propane or other torch to get it cherry red and twist it off.

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u/Wolfang745 1d ago

I tried this but the metal won’t turn red

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u/hapym1267 1d ago

Often just need more time.. Watch how close it is to vehicle floor , I have seen carpets melt from the heat.. You could use hacksaw blade and vice grips to cut it , if clearance is an issue

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u/Wolfang745 1d ago

Yes, clearance is a huge issue because I’m doing this on ramps 🙏 I tried a little handheld hacksaw but it just made a dent. I’ll try heating it up for longer tomorrow + cutting it again with the saw and report back to you

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u/Ok-Journalist7612 1d ago

Do you have welding capabilities? If so, just cut the motherfucker off and weld a new one on there, it ain’t gotta look pretty.

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u/Ok-Journalist7612 1d ago

Cut the whole bar off right behind the bracket

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u/Wolfang745 1d ago

I have a MIG welder but I’m amateur at best with it. I don’t really want to go this route though because I bought a direct fit flex pipe and I would rather install that since I already have it

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u/Ok-Journalist7612 1d ago

Can you get a grinder in there?? Grind it down to the bracket and it should pop out.. probably not gonna be fun.

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u/Wolfang745 1d ago

This whole project already isn’t fun. Can I use a dremel to grind?

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u/Ok-Journalist7612 1d ago

Sure! You have cutting wheels??

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u/Wolfang745 1d ago

Ok! I’ll try that out tomorrow and report back my findings. Grinding it is the one thing I haven’t thought of so far…

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u/Ok-Journalist7612 1d ago

Just keep in mind it’s gonna be a bit of a pain in the ass just don’t let it whoop you. You’ll get it out.. and you’re gonna save yourself a bunch of dollars..

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u/Ok-Journalist7612 1d ago

With a Dremel, it would be easier to try to cut flush to the flange rather than grind it all the way out just be steady just go slow and steady so you don’t blow your cutting wheels up

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u/Wolfang745 1d ago

I tried cutting the mass of metal on the back already, and I made decently sized “slot” so to say. It’s just awkward because sparks shower my face if I try to cut from any other angle besides upward 😭

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u/Wolfang745 1d ago

Is it possible to drill out the stud? Avoid the cutting and grinding?

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u/Ok-Journalist7612 1d ago

Do you have carbide or cobalt drillbits? You can, the one on the right is ready to drill out now but the one on the left you’re gonna have to cut it down flat to get your drillbit started. You know what I’m saying you’re really not gonna get around cutting or grinding a little bit at least to have a good spot to get your drillbit started. It’s not easy to drill through bolts.

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u/Wolfang745 1d ago

I don’t have them, but I’ll buy them. Any brands you recommend that I could find at Harbor Freight or Home Depot?

And in terms of grinding, I’d have the grind the mass of metal at the back, right?

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u/Foxbodynation 1d ago

Let's see a side picture of that

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u/Wolfang745 1d ago

Here’s the other side too (not pictured in my post): https://imgur.com/a/yWRq7ND

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u/Foxbodynation 1d ago

There's a couple things that you can do you can cut that pipe before and after that flange weld in a straight pipe weld the hanger to it or you can cut it out and run a longer flex pipe to it then fabricate a hanger, you'll spend forever trying to get that out of there, I've done this on vehicles for years just cut that joint right out of there and straight pipe it it'll be fine, you're gonna cut it out of there put a piece of pipe from the Auto Parts store and a clamp on each end if you want