patriot993

Hi -

Working on removing mufflers to send to Darin for modification. I have removed the bumper and rear wheels for easier access. But on step #3 ["Loosen 2 nuts at the cat connection(#29) (13mm socket) and slide the clamp towards the center of the car (about 2” is all.)"] I am stuck. The nuts are so rusted I can't get them off. I soaked them in WD-40 last weekend and again today and no luck. I am afraid I will end up rounding off the nuts. Any suggestions? Can I safely cut off with a small grinding wheel on a Dremel?

thanks

Bruce In Philly

Cut em. Use a grinder or whatever and just break them. One shop tech told me that the extreme heat cycling of the exhaust system causes the bolts and nuts to weaken... nothing you can do about it. Same for me when I installed my Sharkwerks x pipe.

The bolt is pressed in from the other side so use a punch on the sheared bolt end and the bolt will pop out the other end. Then go buy some nice stainless bolts and nuts... use metric to keep it all consistent with the car. I purchased some bolts from Home Depot and paid way too much. Some said here those bolts are not any good and recommended others. I figure anything is better than what Porsche put on there.

Peace
Bruce in Philly

patriot993

Thanks Bruce - that is what I figured I would need to do but I read somewhere on the net that using a grinder and subsequent sparks not good idea around car / fuel. I thought that the exhaust gets pretty hot on its own and sparks are the least of my worries but figured I would check with the Rennlist team.

thanks!!

Bruce In Philly

My buddy used a Dewalt BFG: big f grinder on 'em.

Peace
Bruce in Philly

patriot993

it is a pretty tight space for a BFG but will do my best ;-)

awfilms

Get a dremel or use a angle grinder. Your car will be fine unless you have a gas leak which i'm sure you would know about if you did.

Dan GSR

no need to cut
torch them, get them glowing red, they will pop right off
I did two different 997 this way, very easy

Dan GSR

cuting will take longer ,and will probably damage the clamps

Rikky001

Use a small angle grinder and cut the sleeves instead of wasting your time on the bolts. Install new sleeves and lubricate the bolts with copperslip or something similar which is heat resistant and you are fine for years to go.

der Geist

I just broke mine off. I have a set of Sears bolt extractors I used to break them off. Super easy, just tap it on so it grips well and use the breaker bar on the socket. I don't use WD-40 anymore either. I switched to PB Blaster, I read that WD40 doesn't penetrate. I sprayed both sides of the studs with PB Blaster, had dinner and after soaking for an hour they came out with one good whack of a hammer.

Dennis C

When I installed Fisters on my 996, I soaked the bolts overnight with PB Blaster and I was able to remove them. I think it penetrates better than WD-40.

Bruce In Philly

I had mine soaked for days with PB Blaster to no avail..... at some point, the nuts and bolts are just shot.

Peace
Bruce in Philly

patriot993

hi guys!

Thanks for all of the advice. My current plan is to use a metal cutter on my Dremel to carefully cut off the nuts and then hammer out the bolts. I am part way through one nut (my Dremel is of course not too powerful). Unfortunately, I am rapidly wearing out the cutter so will need to get more. I think at this point I am going to have to do it next weekend. :-( I live about 30 minutes from the nearest store that would have Dremel cutters and just don't have time today.

awfilms

Amazon prime my friend

patriot993

Would be an option (I am a Prime member) but am out of town Tuesday - Friday for work so stuck with doing the work this weekend.

With that said, probably will go ahead and order from Amazon so it is here versus me squeezing in a trip to Lowes...

thanks!