HEEEEELLLLLPPPP!

[SRISER]

FINALLY got my Dansk dual out...marked the proper cut lines on the rear valence and then checked out the bolts on the exhaust. RUSTED! I can't get them out or even loose. If I keep at it, there will be zero bolt head to turn. It already is a 12.5mm verus 13mm due to attempts.

So...

Who has done this before and can help get these three little bastards out and help cut a nice line in the valance to install the nice dual out?

Beer and cigar in it for you (okay...and me :D )

The sooner the better...you know how you get when you have a new part to install...

[Rick Lee]

You mean the bolts that go from the cat to the muffler? You should have been prepared for this one - everyone has rusted bolts here. You'll need a dremel tool, maybe an air chisel, definitely a BFH. First time I did this (engine out of the car), we spent a good 4-5 hrs. on those bolts. You have to bite the bullet the first time, bang, hack, drill, heat, curse and destroy the bolts. I assume you have new ones as well as new gaskets too. So be sure to add anti-seize very liberally to the new bolts. This makes the next time (there's always a next time) go much smoother.

[SRISER]

Rick:

Yeah, you're right. I am totally prepared to beat the hell outta the bolts. I have all new replacement hardware and for sure will put antiseize on!!!

You posts from Germany were fantatic. Loved reading and checking out the pics. Very nice!

[jpnovak]

Where in Alex. are you? I have an oxy/acetylene torch. Rusted bolts are no match. Are these the valence bolts or exhaust bolts? paint and torches don't get along. Otherwise, I can help you cut them out.

Jamie
703-778-1606

[Rick Lee]

Oh man, if those are the valance screws, then that's gonna really suck. You'll need one of those hand-held impact wrenches and a BFH. This did work for me a long time ago.

[Charlie Stylianos]

Sam,

If needed, I have a hand impact driver. You'll need to provide the BFH...mine grew legs :roll:

[Vicegrip]

Got all that is needed but can't help out untill Thu afternoon or on the weekend.

[Marc A]

Make sure your replacement hardware is stainless.

[APKhaos]

I think there might be a good reason to avoid using stainless hardware for exhaust applications. Can't remember the reason, but that IS a rule that I carry from some distant past enlightenment.

[SRISER]

Thanks guys. It is the exhaust nuts and thankfully not the valence screws. Charlie, Ted and I are meeting up at Chris L's house out by Chain Bridge on Friday at 4pm if any of you would like to come by and make fun of me...Charlie has a torch, Chris has a dremel, Ted is bringing trash talk and valence cutting knowledge and I am bringing the hardware, tools and cutting disks.

I am using Porsche nuts and bolts as well as gaskets.

Come on by...there will be beer...no Pabst though...sorry Rick.

4112 North Randolph.

[VaSteve]

Thanks guys. It is the exhaust nuts and thankfully not the valence screws. Charlie, Ted and I are meeting up at Chris L's house out by Chain Bridge on Friday at 4pm if any of you would like to come by and make fun of me...Charlie has a torch, Chris has a dremel, Ted is bringing trash talk and valence cutting knowledge and I am bringing the hardware, tools and cutting disks.

I am using Porsche nuts and bolts as well as gaskets.

Come on by...there will be beer...no Pabst though...sorry Rick.

4112 North Randolph.

What a way to round out the week. I really wish I could join you all. I hope you are sucessful, Charlie is a master of the torch.


http://us.f1.yahoofs.com/users/d5c54a87/bc/Porsche/__sr_/PB220078.jpg?phUIx3_AigcXrZ99

Remember, take a lot of photos!!

[SRISER]

I am having vision of a flaming Carrera...maybe Charlie can have beer AFTER we get the bolts off. :shock:

[Jim Richards]

I am having vision of a flaming Carrera
You do know that Charlie is an SC owner? It might be part of their misguided "world domination plot!" :twisted:

[SRISER]

THATS the reason why he jumped in to help so fast...dammit. Fooled by the SCWDP! I will have my revenge...

[Rick Lee]

This sounds like a party I won't want to miss, but it's starting a little early for my office schedule. Which car is Ted bringing? I'm not sure Ted can fit all of his trash talk into his Carrera.

[Parenn911]

misguided "world domination plot!"
Jim, just because we are stronger than the long noses, doesn't mean that we are misguided. :wink:
SCWDP MUHAHAHAHAHA

[Charlie Stylianos]

Sam,

If you bought the Dansk Sport 1/2, it will totally change the way your car sounds....for the better IMHO. I put a Dansk sport 2/1 with SSI's on the 3.0 and it definitely does not have the low rumble at idle or low throaty roar at higher RPM's. Its more of a raspy open flow sound at idle, and a loud whine/scream at high RPM's.

The SSI's probably have a little to do with the change, but it does sound meaner.


Richard,

I'm going to be showing up later...maybe around 6:30-ish due to rush hour traffic and work schedule. You can probably show up later and still have time to BS, etc.

[Trak Ratt]

I think there might be a good reason to avoid using stainless hardware for exhaust applications. Can't remember the reason, but that IS a rule that I carry from some distant past enlightenment.

I also remember a similar warning but it was about using “hardened” steel fasteners on exhausts. The reasoning given was the heat would “crystallize” the steel & make it brittle. I’m curious if the early Stainless was “harder” than now, making it also subject to becoming brittle? Of course you still aren’t suppose to mix metal types. What ever it was they must have overcome the problem w/stainless. I still only use mild steel for general fastening unless it is on a stainless piece. Fasteners is the key word here, obviously if the part being held together has any strain on it you need stronger hardware. Enjoy the party… tis the season!

[SRISER]

Charlie:

I got the 1/2out version, 84mm outs. They are huge compared to the stock so I am pretty pumped up about the sound and looks. 6:30 is perfect. It will take me that long not to screw up my valence. I think Ted will be there to hold my hand as I hack my original, perfect valence...what am I doing? This will be cool.

Rick:
Be really cool if you showed up.

[Rick Lee]

Sam, you do know, of course, that a dual-out exhaust only works when your car is lowered. I don't know how that is, but you can't do one without the other;).

[SRISER]

Now your talking Rick. I do want to do that but I wonder if we would have enough time to re-index while we are there. I'd like the back dropped about 1"...you saw it, it is like a Cayenne.

[Rick Lee]

Your car looks like the Paris-Dakaar rally car. The spring plates a t-bars job on my Carrera was a large catalyst in getting me to buy a 993 and an already-lowered one at that. Charlie is the expert on this stuff. It's a royal PITA. But Ted's car looks so cool that way, that I'd say it's worth it.

[SRISER]

Oh, I though maybe you were offering to assist on Friday... :D

[Rick Lee]

I dunno how I can get there. I get off work at 6:00, hop on the Metro and get home at 7:00 and would have to grab a car and head over. There's no public trans. way to get to Chris' place. Maybe I can get the lady to pick me up at work, take me to Chris' and then watch us work and feed us beers. Yeah, that's the ticket.

[SRISER]

Yeah yeah, that's it. She won't mind that right? Yeeeeahhhh....riiiiggghhhttt.

[Vicegrip]

There are many different alloys of "stainless" steel almost all are not always stainless when subjected to the conditions found on an ex system. Cut and replace is the method most use and for good reason. The cost of a fastener that can withstand the conditions and have the same or close expansion coefficient would cost more than many replaceable fasteners.

Most ex system fasteners are not threaded into a fixed threaded hole but into a loose nut that will fall away and be replaced with new during a repair. If you have a bolt that threads into a threaded fitting you can use a lock washer and lots of copper based anti seize compound.

Another reason to replace is that fasteners will start to fail after X # of heat cool cycles.

RL is spot on. Dremmel or air cut off wheel is great for removing old hardware

[Doug E]

4:00 on Friday ???? Whaddya guys do, work half days or something :wink:

Good luck and have fun.

BTW, Charlie is the master of the flame so sit back and watch the magic.

[SRISER]

Doug:

Just in control of our destiny...or we all work for Uncle Sugar. :D

[Mackpipes]

Good Lord, Why on earth would anyone want to work half day on a Friday!
Doesn't the work week end on Thursday? :wink:
Your tax dollars hard at work.

Ted