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Old 10-12-2020, 04:52 AM   #73
bronsin
 
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Originally Posted by 06YarisRS View Post
Oh man, you know it! If I ever have to do this again, any bolts/studs that won't come out, I'll grind flush with the manifold. Then, remove the manifold, weld nuts onto the bit of stud/bolts that's sticking out. I think my welding nub failed because I'd already compromised the bolt shank by drilling it out. No more male extractor type tools for me! I think I got lucky after the extractor broke off in the bolt shank. Those carbide dremel burring bits saved the day. They chewed up that hardened steel extractor like it was nothing, and it did no damage to the bits. I also got lucky drilling and tapping.

BTW, started the car and it's dead silent up front now. I do need to install an exhaust donut between the cat pipe and muffler at the back. Otherwise, the exhaust system is in excellent shape.


In my experience it’s best to heat rusted fasteners with a torch before trying to remove them. Heated up cherry red. Not often necessary to resort to EZ Out with that approach.
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Old 10-12-2020, 12:17 PM   #74
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In my experience it’s best to heat rusted fasteners with a torch before trying to remove them. Heated up cherry red. Not often necessary to resort to EZ Out with that approach.
Yes, I agree. In this case it was nearly impossible to get anything on it as it was pretty corroded. My mechanic heats them up red hot, then uses an ice cube on the fastener and immediately removes it. Due to the difficult position and the fact that I had to become a contortionist just to get something on to turn the bolt shank, I couldn't coordinate heat, a removal tool attached while holding an inspection mirror in the other hand. Much of this job was done 'blind'. I feel thankful that I managed to drill and tap straight and the nut ended up flush to the manifold. If the engine had been out of the car, it would have been a quick job, I suspect. Live and learn. The next time, I'll know exactly what to do and hopefully it won't be in such an awkward and cramped position.
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Old 10-12-2020, 02:52 PM   #75
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Yes things are a lot tighter these days when working on a car! I’m kind of thankful the car is I got to work on have a lot more space to do so. I would have a difficult time changing a water pump on my 09 Yaris. Even 10 years ago!
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Old Yesterday, 07:07 PM   #76
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Yes things are a lot tighter these days when working on a car! I’m kind of thankful the car is I got to work on have a lot more space to do so. I would have a difficult time changing a water pump on my 09 Yaris. Even 10 years ago!
Missed this. Yeah, I remember the old boats I drove; 69 Olds Cutlass, 70s Buick Century, 80s Crown Vic. You could practically stand in the bay beside the engine. Some day I might buy a classic car and work on it. I can only imagine how much easier it would be, space-wise.
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Old Yesterday, 07:22 PM   #77
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More exhaust work...

I knew I had to replace the little donut at the back of the exhaust system. I got it unbolted and the old deteriorated donut removed Man, it was stuck on there and it took a while to pry off all the little bits.





I started up the car and still...exhaust leak! I plugged the exhaust with my hand and could hear exhaust coming out just above the flange. Dang...the little welded on shield had rusted through at the weld. Seen this before. I got it ground down. The rest of the metal around the hole is very thick and solid.





I just slowly bent a small rectangular piece of old car hood into a curve in my vise. Got the patch welded on.





When I bent the small shield over to have good welding access, I noticed that the other weld had also rusted through. I figured I'd weld that, then weld the shield back on after both patches were done. Ultimately, gave up on that idea. There's a large aluminum shield between that and the gas tank anyway.





Painted with VHT flameproof ceramic paint.



This should hold up for a good while. I would have just put the relatively new muffler I had on my '06 before the swap, but then recalled that I'd put that on my '08 LE before I sold it. Eventually, I'll pick up a Walker SS muffler from RockAuto, ok, I'll keep my eyes open for a Megan or other performance muffler, if I can find a cheap one for sale.

Car is coming along nicely. Went out for a nice drive in it today. Still have a few jobs left to do.

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