I'll let you guys know what happens this afternoon.

Nah, its far from over. I'll drop the header before I call it quits.

I had another idea thrown at me today at work. What if we can spot weld a nut to the top of the bolt?

dropping the header wont work either you cant get the header out with the cat still attached not enuf room to get it out so i was told when i had the same issue.

From what I see, I don't see how that would be an issue. With the connected header and cat free, in hand, you should be able to easily get to all three bolt/nut/stud combos that holding them together....unless I'm really missing something. The only issue I have of not using/trying a wrench or channel locks is the firewall and steering shaft.

Beats me I was told by a reputable source that that method wouldnt work. It sucks that its the drivers side or else you can fit a dremmel down their and just cut part of the bolt..

I wouldn't bother with JB weld. Have you thought about a nut splitter?
http://ecx.images-amazon.com/images/...500_AA280_.jpg

Appreciate the idea and I've never heard or seen one of these. What's stuck is a bolt with no nut on the end. Both the header and cat are threaded at this connector. So, splitting or knocking the top of the bolt head off would only complicate matters I would think, right?

My apologies, I was thinking you had rounded off a nut, not a bolt. Carry on!

Oh, no problem I learned something...never heard of them before; awesome concept.

A friend has these from sears, he told me they seem to work.
link,
http://www.sears.com/shc/s/p_10153_1...4506000P?mv=rr

I still say dremel w/ cutoff wheel.

If anything you can cut a big F'n notch in it, wedge a screwdriver against it, and crank on the other end until something gives.

Absolute worst case, you can cut off the HFC at the flange to remove the header...but I'd try cutting off the bolt's head first.

Torch
 

Torch....................
:tup:

Well, I took it to The Performance Center in Augusta, GA and these good ol country boys got it off. There is no way I could have gotten it off. They could not break it loose with "conventional" tools either. Ultimately, the certified blue tip wrench tech stepped in to cut the head of the bolt off. Unfortunately, he was unable to pull the O2 trigger to start cutting, so all he could do was literally melt the head of the bolt. That finally disfigured the head of the bolt enough that a socket would hold and enough heat to bust it loose. Even after it was broke loose it was no cake walk. It almost looks like the bolt thread has a bur on it or was slightly cross threaded. But, I'm in business now...onto the G3's. Here is the aftermath...

Congratulations on not letting that bolt kick your a$$. Here's wishing the rest of your install goes smoother :rock:

Wow. That is a pretty stubborn bolt. I'm going to assume it won't get reused. LOL.

Haha, No. I told them "good job" when they got it out; "now, put it back".

I'm keeping it and making a shrine for it.