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.

[06YarisRS]

Originally Posted by bronsin

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.

Yes, I agree. In this case it was nearly impossible to get anything on it as it was pretty corroded. My mechanic heats them up red hot, then uses an ice cube on the fastener and immediately removes it. Due to the difficult position and the fact that I had to become a contortionist just to get something on to turn the bolt shank, I couldn't coordinate heat, a removal tool attached while holding an inspection mirror in the other hand. Much of this job was done 'blind'. I feel thankful that I managed to drill and tap straight and the nut ended up flush to the manifold. If the engine had been out of the car, it would have been a quick job, I suspect. Live and learn. The next time, I'll know exactly what to do and hopefully it won't be in such an awkward and cramped position.