First off, I canâ€™t take all the credit for this â€œHow Toâ€, as Ralph, George and a lot of others will tell you this is how to get a frozen exhaust pipe out, but I hadnâ€™t seen anyone post pictures of the process so I went ahead and did it.
Materials List: One 1â€ threaded nipple (about $2 at Home Depot), hacksaw or Saw-All with a metal cutting blade, grinder (preferably a handheld unit as it is easier to handle it and not the manifold), 2 lag bolts, scrap piece of 4X4.
Not only was my exhaust pipe frozen into the manifold,
It was welded in as well!
The casting can be fragile, so I chose to mount the manifold to a piece of scrap 4X4 I had laying around with 2 lag bolts. This way itâ€™s easier to mount the 4X4 into a vice, and thereâ€™s less chance of you breaking the manifold by trying to mount it alone into a vise.
Using a hacksaw, or a Saw-All if you have one, cut the pipe off as close as you can to the flange of the manifold.
Using a hand held grinder, or bench top grinder if thatâ€™s all you have, slowly & CARFULLY grind the material down flush to the top of the manifold flange.
You want to try and just get the material down to where you can just make out the outline of the pipe that is threaded into the manifold.
Now the scary part, using a hacksaw blade, or the Saw-All if you are BRAVE enough, you want to cut 4 slight cuts inside the pipe, just enough to barely touch the threads.
You should be able to â€œPEELâ€ the pipe from inside the manifold using a cold chisel, pliers, etc.
After you get the pipe out, you can either: 1) Purchase a 1â€ pipe tap. 2) Find a plumber friend who has one to clean up the threads, Or 3) Make your own tape using a 1â€ threaded nipple.
Cut an â€œXâ€ (4 slots) into the end of the pipe, and I then drilled a Â¼â€ hole in order to use a drift punch as a handle to turn the tap. I chose not to use a pipe wrench as I have already stated, the manifold can be fragile and if you apply too much pressure you could easily break it. Doing by hand is best, as you can "Feel" if you are putting too much pressure on it.
Insert the tap, and slowly turn it in. You will probably have to repeat this slowly and gradually. Use some penetrating oil to help lubricate the tap as you go.
Sorry â€œCountry Elliotâ€ I can only get â€œPB Blasterâ€ locally around my parts!
Take your time and with a little patience, youâ€™re done.
When you â€œRe-Installâ€ your new exhaust, be sure to use some anti-seize compound as you donâ€™t want to have to go thru this again.
Good Luck, Mike Duncan (AKA: Into Tractors)