The Bolts from Hell...
 

Pics will be up sooner or later, but I bought a pair of short tails from someone on the forum. They arrived last night, and my friend and I attempted to install them, seen a video, only the midpipe-rear section connection and exhaust hanger removal, then reverse for installation, done.

So I spy some rusted studs, clean nuts on the midpipe and rear section connection. Try to unbolt one. Doesn't work, rusted, makes sense.

Spray PB Blaster. Wait 5 minutes. Nothing. Mind you I'm still using hand tools.

Spray more PB Blaster. Wait 10 minutes. Tap the bolt a few times with the ratchet. Attempted, got nothing. Frustration builds, but still patient, having dealt with rust before.

Spray even more PB Blaster, on all the connections for the exhaust. 4 studs and nuts. 10 minutes later with constant tapping, I try again, to no avail. Even heated them with a lighter (not much heating going on there... lol).

Frustrated enough that I spent about 50 minutes trying to turn a single bolt, I thought about some research I did before I replied to a thread here. Someone did a homebrew of autotranny fluid and acetone, 50/50.

I went to Walmart, bought some ATF meant for pre2006 ATs. Not a big deal, I figure. Buy some acetone from the painting tools section.

I mix them half and half (it's really an odd looking concoction, almost like a strawberry smoothie or something; wouldn't recommend drinking). I saturate the bolts using half of a soda can. Still nothing following the next 30 minutes. I figure I'll try it later, so I properly heat them, drove about 20 minutes in decent weather (75 F) and went WOT a few times. You might call it spirited.

I haven't tried to turn a wrench on it since the drive. I am asking around for air tools later today and into the weekend. Who knew that installing short tails would be such a headache!?

Any suggestions from anyone? You know, besides finding air tools.

Galvanic corrosion my friend..an excited car enthusiast with some new hardwares worst enemy!

I ended up having to cut the bolt heads out and drill the body of the bolt out and just replace the bolt. I had a buddy who had great success with driving the heck out of the car for awhile to heat the bolts up and then trying.

*** Nevermind - I see you already tried driving the car to heat the bolts.

Since the driving around I haven't turned on them. I'm going to WOT like crazy on the way back. Maybe I can get them to crack.

Since the car has been stock for three years and 11.5K miles, I'm willing to bet the stud and the surrounding metal have become fused... essentially a solid piece of metal. There's still a good coating of the homebrew penetrant so maybe I can just bury the throttle and get lucky... otherwise I'm gonna have to find some advice about how to drill out the bolts.

I've got a weekend free before more work comes my way, so I might just continually soak the bolts in penetrant. 24 hour working time!

Also, 24 Heures du Mans. Yes.

Use some real heat, driving around or using a lighter will never work. Acetylene torch, propane or butane torch to heat until glowing will do wonders for rusted nuts/bolts.

Power tool :confused:

get a long regular wrench, not a socket. Put it on the bolt and precede to beat the **** out of it with a hammer. Thats how I got mine off. Make sure you use the closed side and dont strip it! WD 40 was all I needed.

low tech way is after you blast it with WD40 or the like, use a small hammer and tap at the bolt. that usually breaks the rust free.

then put a closed wrench on the nut, use a mallet (wear goggles) and tap at the wrench real good hitting it counter clockwise. should work just as good as a small capacity impact.

also i recommend you get a 18v impact driver. 150lbs/ft is more than plenty to do most work. for heavy duty you'll want a higher capacity unit, preferrably airtools as the wrench itself is much smaller and easier to access suspension bolts, etc. i dont have air tools (due to stupid HOA rules for noise) but no issue with the 18v and breaker bars.

Bigger wrenches or at least a torque multiplier.

I haven't met a bolt I couldn't break loose, or snap off, with some PB blaster and 1/2" sockets. Even with normal wrenches, it's not that hard.

the issue here is he needs burst power (impact), not so much torque.

and watch, the bolt head will break off. :rofl2: do at your own risk. :tup:

The torch idea seems like a last resort, which you have come to I'm afraid. Good luck.

I hope I do not encounter this type of problem next month when installing my exhaust and HFC. I do not have as much patience. I will break something.

Do all your mods in the first month of ownership! Avoid the problem! lol :stirthepot:

Get a set of grip-tite sockets and at least a 1/2" breaker bar. I used 3/4", but I know not everyone has a set that large. Find a pipe to go over the 1/2" breaker bar to extend the leverage of it.

:icon17:

:iagree: Same thing happened to me... I just cut the bolt heads off