Just the usual...
Soak the nuts in penetrating fluid muc as possible, ie, a few days in
advance and re-apply often as possible.  Use something like Kroil or PB
Blaster.
Then use a propane or oxy-acetylene torch and heat the nuts, then re-apply
the penetrating fluid.
Then shock the nuts with a little hammer.  Tap em like 100 times or until
your arm is too tired to continue.
Then use a six point socket or box wrench only and try to break lose.

Then after the stud breaks off flush with cylinder head:
machine flat, drill out and helicoil :)

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of J
Stewart
Sent: Friday, July 02, 2010 8:30 AM
To: vanagon@GERRY.VANAGON.COM
Subject: Removing Rusty Exhaust System

OK, if you read my last post you saw I found an exhaust system. My current
one is in really bad shape, the rear pipe was cracked, welded, then cracked
again at the weld and has cracked completely in two in another spot. Now,
looking at the exhaust port at #3, the nuts are so badly rusted that I know
they are going to snap off when I try to remove them, leaving whats left of
the stud in the head. Any suggestions? Thanks, Jeff

Jeff Stewart
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