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[Terbs]

Got the arris end up on ramps, mate....been gassing for a week now. From my limited engineering experience, there is no way I will be unscrewing those bolts. I reckon they will snap at the first turn. They are well corroded If the bolt snaps flush on the cat bracket, I expect I could possibly drill it out, but how the hell do you get it out if it snaps at the bolt head end or in the middle??

[amba]

Its not such a big problem if the 2 bolts shear off as its better having a nut,n,bolt securing the new pasrt together imho.

Plenty of Plusgas will see them come out if you go steady on the wrench

[amba]

Big set of Irwin mole grips and just wind it out if it snaps bolt head end or mid way.

If lush get a good HSS colbalt drill with some oil to lubricate the drill bit and you will be fine 

[Terbs]

I've cleaned everything up, wire brush, gassing it, etc....now I can't get a spanner to fit   11mm too small 12mm too big, tried 7/16 af, 1/2 af both no go. What the heck size am I looking for 

[Jimbob]

Ive had that before now...and found an old whitworth that fitted!  Beyond me!

[Terbs]

Been all through my spanners and sockets, and no joy. Thinking now that I might bite the bullet and saw the bolt tight to the bracket, and then drill it out to take a new bolt and nut, it will still be held on by the bolt on the other side.
Question is, if things go wrong, would that single bolt be enough to hold the exhaust together for seven miles to the garage

[CaptainZok]

Does your son in law have access to a hot spanner?

[Terbs]

Forgive my ignorance, Capt'n, but what is that

[tunnie]

Gas torch?

[amba]

A bit of gas from a torch 

I would have thought just 1 bolt securing the pipe would not make an edequate seal so exhaust would be blowing like mad

Try running a square edged file across the flats of the bolt head to get a decent shape...then try hammering on a 11mm if is just slightly too tight

[bigtow]

i fitted my exhaust from this company fitted ok only issues are the rubber hangers are a bit smaller than the standard ones and one of  the tail pipes was slightly bent down but easy fix with a pair of big pliers very good for the price and oh so quiet   

[CaptainZok]

Forgive my ignorance, Capt'n, but what is that

Get it cherry red with an oxy torch then try to wind it out.

[Terbs]

Thanks very much for your help and advice/tips etc......but I am going to give it best. I'll sweet talk the son in law. It has to go to him for a bit of work prior to MOT, which can't be done before the 12th. I have a 2.6 cat here and the joining bracket is built like a brick outhouse. The 2.5 is like a piece of tissue against that. If I drill it out, I'll also have to saw off the threaded extension of the cat bracket, so a new nut would butt up. The new bolts are thicker than the existing, so the bracket would have to be drilled out too.
Pics show what I mean...............

[Andy H]

That looks a bit odd to me, almost as if someone has already drilled out the screw threads and fitted nuts & bolts

[pirate]

when my longlife system was fitted the joints were so crap to cats he cut them off and tig welded new flow system direct to it .