Date:         Wed, 30 Mar 2005 07:36:20 -0600
Reply-To:     Wesley Alden Pegden <wes@CS.UCHICAGO.EDU>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Wesley Alden Pegden <wes@CS.UCHICAGO.EDU>
Subject:      Major exhaust woes! (Stud replacement???!!!)
In-Reply-To:  <20050326161210.GA3387@the-400.cs.uchicago.edu>
Content-Type: text/plain; charset=us-ascii

First, thanks to everybody who responded to my previous emails.  It looks like I'm going to have to replace all my pipes:  They're rusted all the way through in 2 places: only the rear header pipe is hole-free.  I began the process of removing the olds system even before ordering a replacement---and I see now that I have what look to be some difficult problems.  I succeeded in removing everything but the front-side header pipes (that connect to the engine and the collector pipe).  This pipe is attached with studs, not bolts, and the studs (and bolts on them) are rusted real bad.  Even if I managed to get the bolts off, the studs themselves are totally unusable (i.e., no thread left).  So, I probably need to be replacing the studs.  How can I do this??  I've seen some crazy info online on methods that involved some welding.  Do I have some more accessible options?  I'm out of the country now for 2 months, so I have time to plan and order things that I need before I can attempt this again, but, ideally, I'm hoping the job will be doable when I get back.  I also really can't afford to spend too much on the exhaust....  That said, I don't want to do this again.  It looks like Busdepot's exhaust replacement set is 299.  Is this my most reasonable option?  Since I'm doing all of them, I don't want to replace them with something already rusted.  Then again, it feels like a lot to spend on smoke redirection.  I'd also appreciate any pointers on DIY coating kits---I've heard of coats that you can bake on, for example, that might be inexpensive yet effective.

Thanks very much for any help. 

BTW, the (in)complete story was:
My catalytic converter died most of the way from Pittsburgh to New Jersey.  (Very) shortly thereafter, My OXY sensor blew out of the collector pipe, I guess due to the pressure.  After that, My van was loud, but I had to drive it back to Pittsburgh before considering replacement options.  I picked up a cat and muffler from Bus Depot outside of Philly on the way..., only to decide on my return to Pittsburgh that my problems were much worse than I had hoped.

Thanks a bunch guys,
Wes