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[hawke113a]

me got a slightly large problem....i was fitting a new exhaust and the damn bolts on the centre to front pipe have snapped.now my poor car is sat and i dont know what to do.i have two options i can either drill out the remainder  of the bolt or i have a elite v6 that i am scrapping on tues.is it a big job to remove the front pipe from the manifold,i have to go in from the top of the engine cos the car is dead and i cant get it up on ramps.any ideas guys

[doz]

Can you not drill it out while it's still on the car? You must have it up in the air to get to the exhaust. 

[albitz]

They always snap and need to be drilled out.It can be done in situ but its a real pita.Easier overall to take the cat section off the car ime.Just two nuts up at the manifold.Need a couple of socket extension bars and possibly a knuckle joint,but not that bad.
Use cobalt drill bits if possible,run the drill quite slowly and dont push too hard against it. Start with something like a 3 or 4 mm bit and then iirc follow it with an 8 mm bit.You may be able to then clean the thread out with a tap, or simply use bolts & nuts of a slightly smaller diameter than the originals.
Hope that helps.

[Elite Pete]

Its a common problem. Grind the remaining thread flush with the flange and then drill them out starting with a small drill bit and work up in size. Replace with stainless nuts and bolts just in case you have to remove them at some point in the future  

[feeutfo]

Cat to mid section bolts?

Grind them flat if needed. Drill the buggers out. As Pete says.

[hawke113a]

Cheers guys

[hawke113a]

yeah i won the first round.bolts drilled out and the thread still there.the pipe was easy to get off now all i have to do is fit the new exhaust.