Exhaust tail pipe replacement.

[Dad]

Ok, my existing tail pipe (1.9 dg) has a hole in it, I have a nice stainless replacement from mr Baxter, but after looking at the bolts holding it on they are all rounded (I can't even guess what size they were!) so the question is;
What is the best way of removing the bolts? Cut and drill? A slot and a screwdriver? A exhaust man?
Thanks in advance, Nic.

[itchyfeet]

Hard to get in but whatever you do if it's a late van you can drill out 9mm and get nuts on the back, they are M8.

I just drilled mine out and fitted stainless nuts and bolts when I first fitted it.

[Dad]

Thanks, probably the easiest.

[itchyfeet]

Is it a late silencer?

if so M8x25, not sure if early is the same

When you drill through be careful not to punch through the silencer as itfinally breaks through, easily done, stick some sheet metal in between the flange and the silencer. Drill metal at slow speed.

[Dad]

Cheers itchy, looks easy, I kinda knew not to drill in to the box! Yes it's late 1990.

[chuckle-bus-tom]

Just use a junior hacksaw between the silencer and tailpipe, no need to mess about.

[Dad]

Mmm...

[crazyhorse]

Hole in the back of mine. Have managed to hacksaw just before the hole, but fumes go directly 90 degrees now rather than downward and it's rather short now also (is that a MOT Fail??)

Got replacement for £20

Bloody hell it's a right git to get off. Bolts rounded. No way I can hacksaw the joint, too awkward. Left handed and no way with the heat shield in the way.

Drill.... not to sure what I am doing that way. Is it a case of just drilling into the bolt?? Knowing me I would drill at an angle or something

Will take the whole silencer off I think, though i remember that being a pain with the brackets to get it out

[itchyfeet]

4 inch angle grinder

[crazyhorse]

4 inch angle grinder

Christ, never used one let alone got one.

Would be carnage if I had one I reckon

[chuckle-bus-tom]

It'll be nibble, but a junior hacksaw will get it. Mine rusted off so I filed it smooth and left it off. No MOT fail.

[itchyfeet]

You could sit there spraying it with salt water and waiting for it to rust off

[Dad]

So the update. I used a 4" angle grinder with a thin metal disc, it went through the bolts in about 4 minutes, the top bolt was a little harder. Then I notched a V in the silencer flange at each bolt to release the rusted bolts. Then just bolted the gasket and pipe on (this was a bit of a pain). All in all about 1 hr work.

[chuckle-bus-tom]