Date:         Mon, 18 Jan 2010 13:10:41 -0800
Reply-To:     Aaron <a.robinson.lists@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Aaron <a.robinson.lists@GMAIL.COM>
Subject:      Waterpump and exhaust and rust - Oh my!
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Hi All. 

This is a special topic that I - living on the west coast have never had to deal with. I have an '87 van that spent 10 years in the east. It came to me with a rotted exhaust and recently a waterpump that started leaking. I figured that its about time to attack it and thought I would do it all at once. So I got a start removing the exhaust this evening and realized that the exhaust is going to be hard for an un-skilled chap like me. Every bolt head is so rusted that it doesn't really have sides on it. 13mm doesn't fit...12mm is still too big. Vice grips just remove rust. I did manage to get the tin off, torque one header bolt head off and get the muffler and cat removed. Most of that was done using a sawzall. That "only" took 3 hours. Now I have all of the hard ones left. 


So my first questions in this undertaking are: 
What's the easiest way to remove a rusty exhaust (especially the studs in the heads)? Is there some special secret? Some tool that turns a helping of inept-ness with a few tools into success? 

I have a gently used exhaust, new gaskets and bolts waiting. I just need to figure out the easiest method of getting the old one out of the way. I have available: a plumber's torch, wrenches & sockets, hacksaw and a waning desire to not pay someone else to do it. 

Thanks!
Aaron 
'87 westy (in WA with van from Illinois)