shortyboy

does anyone know what is the correct size to replace the exhaust nuts and bolts(where the crossover meets the headers).also,does anyone know the saturn part # for the exhaust manifold studs and nuts.i took off my headers to check for cracks,is there any way other than visually checking them,like pressure testing them or something.i might just reweld,but if i can find a good set of headers ill just replace em.im going to take off the heat sheilds,is there any easy way of taking them of other than prying them off?i guess im one of the lucky ones that didnt break a stud,that could be due to me spraying them with pb blast and letting them sit for a few days.my plans are to check for cracks,if there are try to get them welded or replace,take heat sheilds off and wrap with DEI header wrap.thanx and please feel free to input your .02 cents.

awilson40

As a side note... Is there a reason why studs are required?
When I replace mine, I was wanting to use allen head cap screws.
Is there a reason not to so this route??

special tool

shorty - that is an excellent plan.

pikey7

Don't bother with the cap heads. They will only be any good if you have great access. And you don't on those! You'll strip them after 5 minutes heat cycling!!!

Stick with the standard studs, but fit some copper nuts. The material combination is a bit more friendly to them "welding" together.

hosrom_951

My headers use 12mm bolts, no studs or nuts.

painkiller

Shorty, Saturn pn 11518152.

John

shortyboy

btw,does the flew pipe on the headers actually flex(like move),cuz i can move it a little, like its loose.

special tool

Yes

Crazy Eddie

Laust
Posted the Saturn studs becaues they had a torx end
They require a socket that you will have to buy
I have both but have not yet installed them.
They are a M8 stud and the outside nut can vary depending on the manuf.
Paragon has a great deal on those nuts ..Jump on'em
I have a boat load of new exhaust bolts and nut, better than factory specs
PM me if you are so inclined
Regards
Ed

shortyboy

pm'd

shortyboy

btw,does anyone know wherte i can find the saturn studs online?my local saturn hasnt have any in stock and will take a few weeks to get them.is there an easy way to take the heat shielding off of the headers?thanx

Crazy Eddie

I took of the heat shields ...I don't know if I would go that route again
They were really not that hard to take off until the last bolt ( the allen head at the top that
mounts to the side of the block ( it was an absolute bitch !!)
My allen head socket set was either too long or too short I could not get the right combo
There is a post on this with Danno describing how to do it
One word of advice I could not for the life of me get off the headers with out at least pulling the
the #4 studs the Freaking headers wouldn't come out ... but for the sound of it you will be replacing the studs...
The other method it to remove the Eng. mount bolts on the pass side and carefully jack the car by the oil pan with a substantial wood block ... I was a bit afraid of that route because I have a very slight
oil seepage and didn't want to make it worse
Regards
Ed

z3bra

If you have a VW bug performance oriented shop in your area check there. They usually keep Copper 8x1.25 Nuts in stock and they're generally pretty inexpensive (maybe $10 for a package of them if I recall correctly).

If you don't go with copper nuts, definitely use some copper (1800 degree F rated) or Nickel (2400 degree F rated) anti-seize on the studs on the ends that the nuts go on. Use it on all your turbo exhaust studs and so forth if you want to make things easy on yourself next time you need to take it apart.

shortyboy

update:i took the heat shields off and it too about 1hr 45mins.at first i used my dremel to try and grinds off the welds.then i used a hack saw and slotted the spot welds on the heat sheilds.but the best method was to slot the sides of the heat sheilds and then use a big creseant wrench to work the metal back and forth until it broke off.well heres what i took off and what the headers look like now.im going to clean them tomarrow and check for cracks,if not im going to get the flanges welded for extra measure.im still thinking of which way im going to go with my headers.its either DEI wrap,jet hot coating/or equivallent or some thermal jackets.thanx

sm

Beware...I heard the heat shields and insulation contain asbestos.