97 Integra GSR

My stock exhaust split in half right after the resonator due to rust. So I picked up a Thermal R&D Stealth cat-back system (full stainless).
Last night I was trying to get the old exhaust off. The bolts & nuts at the back of the cat were so rusted that it was impossible to get the nuts off (sprayed them, used vise-grips, etc.). I thought there was no way I could reuse those bolts since the threads were all rusted, so I sawed off one of the nuts (and 1/2 a bolt). I figured the rest of the bolt would just fall out after cutting the nut off, but I guess it's pressed in there or something because it won't budge. Anyone know how these bolts are attached to the cat? And what's the best way to get them out of there? I can try to drill them out, but it was really hard to saw those things off (even using a power-saw). Either that or buy a new cat.

If anybody out there has had this problem, please let me know what you'd suggest I do. Thanks.

 

I had the same rust problem. I just took my car to Meineke and they loosened all the exhaust bolts for me for $7.

 

In your case, I'd get a bolt that's one size smaller and pound the rest of the bolt out.

 

I would unbolt the cat from the header. It's easier to take off those two bolts, than the three on the b pipe. Plus you can use a socket wrench to remove the header bolts. Once it's out from underneath the car, you shouldn't have any problems removing the 3 rusted bolts.

 

I could be wrong but aren't the bolts on the cat that connect it to the exhaust welded on the cat? It is part of the flange. You should have used a nut cracker and broken the nuts & not cut the bolts.


98 Integra
92 Civic
90 CRX

 

You're right, those bolts are attached to the cat and not supposed to be cut. If you do cut anything, it should be the nut.