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I just ttried to install my DC Header and ended up stripping the living crap out of the 2 heat sheild bolts. I tried everything from torque wrences to wrenched with a defensive pole locross stick for leverage to vice grips and the damn bolts would not budge. all the others cracked the seal with minimal pressure however the left one needed to be hammered (the wrench that is). But now i am left with one rounded bolt and another that is rectangular becuase i tried to file it down to get 2 flat surfaces in order to try it again.

I am screwed. The only thing i haven't tried yet are the new craftsman stripped bolt remover thingies that my brother (aeronuatical engineer w/airforce) says are the magic tool.
I called honda and they said bring it in but it isn't covered under wuarantee. If those damn things are rusted stuck it better be inder wuarantee. So before i have them drill into my manifold and retap the crossthreads i was wondering if anything like this has happened to anyone and what did they do?


PLease, someone have an answer!!!!!!!

 
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I would heat that B_tch up with a torch, get it glowing red, then twist it out. i have used this technique on other seized bolts with success. in your case you would then need to get a grip on that rectangular head, vise grips maybe. lets see what others say.

 
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use a plasma cutter. itll get the job done

 
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I just tried replacing my header last night... the manifold cover bolts and the bolts holding the header on all came off relatively easily, i cant figure out how to get the bolts holding the header to the downpipe off without lifting the car way off the ground which I dont want to pay to have done, anyone have any ideas, I cant get my hands and a tool under the header to the bolts on the downpipe. anyone else had this problem that can make suggestions?

 
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you go to wallmart buy 2 jack stands for 10 bux and a 2.5 ton jack for 30. Also buy a 10 inch extension for you ratched. and walla. That's what i did. those were easy.

 
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Rusted bolts aren't covered by any sort of warantee. I know this from working at a dealership. Exhaust bolts are the only ones I have ever heard of having a problem with rusting, but they are easily cut out. I would try the stripped bolt thingy, they do work from my experience. If that doesn't work, get a torch. And if nothing else, cut the freakin het shield off completely.

 
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your ****ed, j/p man. but my friend had to take his to a shop because we could get the bolts off.

 
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Maybe try spraying it with some PB Blaster to help lubricate it then use the same methods again. Or go buy a screw extractor(ez-out) and see ifthat'll help. With a screw extractor, you drill a hole into the bolt or screw, hammer in the extractor and pray to the gods that you can back out the stuborn bolt/screw. Do a google on screw extractor and you'll see what I mean.

 
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Here is the secrete to seized boltz... Go to sears and but the stripped bolt removers. they come with 5 to a set for 20 bux. just get them to have becuase they can remove any bolt and cuase lil damage to the bols so they are very good for removing bolts for the first time. I used it on every bolt and reused all the bolds except for the to i stripped beyond recognition.

Also buy Gunk liquid wrench. Put it on the engine bolts when hot. and let it sit for about 10 minutes. Grap a long wrench or torque wrench and tug away. Boom like butter.

Mu header is now on and NO BOLT IS TO SEIZED. I am happy as hell.

Once again thanks to all for your sugestions

 
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Congratulations! thanks for the follow up, good info.

 
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Damn i got to slow down when i type!!!!!!!

LOL hope you all can decipher my scripted language above!