2007 "Red Yaris" RS Restoration

[bronsin]

Originally Posted by 06YarisRS

Oh man, you know it! If I ever have to do this again, any bolts/studs that won't come out, I'll grind flush with the manifold. Then, remove the manifold, weld nuts onto the bit of stud/bolts that's sticking out. I think my welding nub failed because I'd already compromised the bolt shank by drilling it out. No more male extractor type tools for me! I think I got lucky after the extractor broke off in the bolt shank. Those carbide dremel burring bits saved the day. They chewed up that hardened steel extractor like it was nothing, and it did no damage to the bits. I also got lucky drilling and tapping.

BTW, started the car and it's dead silent up front now. I do need to install an exhaust donut between the cat pipe and muffler at the back. Otherwise, the exhaust system is in excellent shape.

In my experience it’s best to heat rusted fasteners with a torch before trying to remove them. Heated up cherry red. Not often necessary to resort to EZ Out with that approach.