So I installed my ZOMGRICERBLING cat-back system today, and at one point, due to rusted bolts, I needed to unbolt the downpipe from the header (long story). It is a round-sided, triangular flange with connections at each corner, pretty standard stuff. Each has a nut threaded onto a stud that has threads that thread into the upper flange, and pass through the lower unthreaded flange. Turns out, those were damned rusty too, because I snapped one of the studs clean off. There is engine cradle 2" to the front, and engine block 1" to the back of this snapped stud, so there's absolutely no room to get vice grips in there, and I don't have a welder, so welding a tab to the stud and twisting won't work, and there's no room to spin it anyway. Above the upper flange, there is a gigantic pre-catalytic converter catalyst (thank you, Commufornia) so access from above is severely limited as well.
My options: 1. Do nothing- but the thought of 1000* exhaust gases flying out of the one corner aimed directly at the coolant inlet hose doesn't make my socks roll up and down. 2. Clean the rust off of that corner and JB Weld the two flanges together- not ideal, and I'm screwed if the downpipe needs to be removed/repaired in the future. 3. Drill the stud out somehow- GRM will have to school me on this one, and I don't have metal drill bits, so this will require spending more money. 4. Buy another header from the boneyard- but it's 150 miles round trip, and since it has a tiny catalytic converter welded to it, it's sure to be expensive.
What would you do?
