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[robson]

Just a thought about the doctor cutting a slot in the flange. Could you not take the slot passed the flange and cut through the bolt releasing the grip?

[omega2018]

yes that would cut out the hammer bit

so DG you have a flange which bolts screw into, the bolts seize on and rather than simply drill them out you want to take a grinder to the flange, remove a large slot in each side,  bash out the bolts (as robson says why not simply keep going with the grinder and grind them away) and then try and fix on the new exhaust to the remains of the flange. which has been weakened with two large slots and is technically no longer a flange. two half flanges if you like.  have anyone ever seen a fitting designed with two half flanges instead of a flange?  does that tell you something?

[Doctor Gollum]

Just a thought about the doctor cutting a slot in the flange. Could you not take the slot passed the flange and cut through the bolt releasing the grip?

Cut upto the bolt using a dremmel rather than an angle grinder. Then open the slot with a flat blade and tap the bolt out. Replace with a size smaller bolt, washers and lock nut.

Carefully slot the outer edge of the flange in to the bolt/stud, apply heat and smack it out with a suitably sized hammer.

On reassembly, use bolts and washers. Done

From experience, the flange on these aren't strong enough then going forward 

Done on both my estates and neither had the exhaust fall off. Wouldn't have suggested it otherwise. 

[terry paget]

yes that would cut out the hammer bit

so DG you have a flange which bolts screw into, the bolts seize on and rather than simply drill them out you want to take a grinder to the flange, remove a large slot in each side,  bash out the bolts (as robson says why not simply keep going with the grinder and grind them away) and then try and fix on the new exhaust to the remains of the flange. which has been weakened with two large slots and is technically no longer a flange. two half flanges if you like.  have anyone ever seen a fitting designed with two half flanges instead of a flange?  does that tell you something?

I think you misunderstod DocG. He suggested one cut for each bolt, in from the outside as far as the bolt, then prising open the flange slightly to allow the bolt to be bashed out. Robson suggested continuing the cut throught the blot as well, releasing it as 2 halves. Either way, enought flange remains to do the job.

[Doctor Gollum]

He didn't misunderstand. Rather being deliberately obtuse

[omega2018]

yes that would cut out the hammer bit

so DG you have a flange which bolts screw into, the bolts seize on and rather than simply drill them out you want to take a grinder to the flange, remove a large slot in each side,  bash out the bolts (as robson says why not simply keep going with the grinder and grind them away) and then try and fix on the new exhaust to the remains of the flange. which has been weakened with two large slots and is technically no longer a flange. two half flanges if you like.  have anyone ever seen a fitting designed with two half flanges instead of a flange?  does that tell you something?

I think you misunderstod DocG. He suggested one cut for each bolt, in from the outside as far as the bolt, then prising open the flange slightly to allow the bolt to be bashed out. Robson suggested continuing the cut throught the blot as well, releasing it as 2 halves. Either way, enought flange remains to do the job.

yes thats what I thought.  except the 'prising open the flange' bit which is new.  so you cut two slots into each flange, one for each bolt, thus considerably weakening the flange.  Then you prise open the weakened flange at the two weak points you have just created.

its genius 

i'm surprised DG didn't design for Vauxhall this is a big improvement on their original flange-with-two-threaded-holes design.  a flange with two dremel hewn slots, prised open with a  lever.  what could be stronger than that?   on a system prone to massive temperatures and rust.

[Doctor Gollum]

Go fuct yourself.

[TheBoy]

OK, Doctor Gollum and migmog, you're both in the last chance saloon.  Grow up, FFS 

[Doctor Gollum]

If the notch bothers you, two minutes to weld it back up.

[omega2018]

If the notch bothers you, two minutes to weld it back up.

so it's

dremel cut flange, prise apart, hammer out bolt, prise back to original position, get welding kit out, weld up the 4 cuts you just made

v

carefully drill out bolts.

hmmm...

[Doctor Gollum]

I was talking to TB

[Marks DTM Calib]

You have a plasma cutter, cut the bolts flush and use the cutter to blast a hole through the middle.

Then gently increase the hole size until the bolt remains fall out.

[TheBoy]

You have a plasma cutter, cut the bolts flush and use the cutter to blast a hole through the middle.

Then gently increase the hole size until the bolt remains fall out.

That thought had crossed my mind yesterday.

Would the ECUs need disconnecting, like when welding?

[TheBoy]

To nut and bolt it back together, do I use, say SS nuts and bolts, or BZP high tensile etc?

[Nick W]

To nut and bolt it back together, do I use, say SS nuts and bolts, or BZP high tensile etc?

Don't use stainless if you ever want to take it apart again. Buy good quality BZP from a proper fastener supplier, the four bolts and nuts you need will give change out of a quid.