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How to Remove Exhaust Flange Bolts Easily?

Although not in our supply chain, we have had a few questions regarding other types of flange bolting and installation. Here is a basic guide to exhaust flange assembly.

Exhaust flanges consist of a pair of metal sections that join your exhaust pipe together. They are helpful in conjunction with an exhaust set of bolts and gaskets. The usual options of exhaust flanges are the 3 bolt or 2 bolt types. Usually, m10 with the 2 bolt option is helpful, and an m8 bolt for the 3 bolt. The recommended grade of bolts is 8.8 tensile or higher so that you can tighten them without stretching or breaking the bolts. There is also the use of locking nuts, Loctite, or spring washers. It helps to prevent the nuts from vibrating loose.

How Exhaust Flanges Work

Exhaust flanges work with the use of a set of bolts and gaskets to join them together. When you set up a wastegate pipe or exhaust for ease of fitment, you must use v bands or exhaust flanges to enable the sections to re-fit or pull off for access. You can also use exhaust flanges without gaskets, and for that, you need to use automotive-grade silicon.

How to Remove Exhaust Flange Bolts Easily

Welding Exhaust Flanges

Welding exhaust flanges are almost the same thing as welding v band flanges. The essential factor to start with is tack welds every 20-30mm. It helps prevent distortion stitch weld the flange and let it cool down between welding.

How to Remove the Exhaust Flange Bolts

The changing temperatures from cold to hot of the exhaust system together without changing the moisture conditions can result in speeding up the rusting of the flange bolts. If the rust progresses, it could reach the threads, and these may go useless. It is essential to replace and release the flange bolts. You need to apply heat to remove the rust from the threads. If the threads are unusable, you need to cut the bolts from the flange.

Here are a few easy steps to remove the exhaust flange bolts easily:

Keep a check if the area on the flange bolts has no fuel lines as well as combustibles. Clearance of all the combustibles underneath the vicinity for safety is essential.

Use gloves and goggles to protect your hands and eyes.

It is better to have a fire extinguisher closer in case the fire starts.

Ignite the torch carefully. Make sure that the bright blue flame is half or one inch long.

The tip of the torch must be 6-8 inches away from the flange bolt until it has a dull orange color. You need to turn off your torch. Heat the bolt slowly and do not use air to trigger it.

It is better to let the flange bolt cool down and place the socket that fits the bolt to the ratchet.

Slide the socket to the nut that is at the flange bolt. If the bolt loosens, continue with the same process for the rest of the bolts. If it doesn’t budge, go to the next step.

Keep the tip 3-4 inches further and set the flames again.

Heat the bolt once again and when it turns to a bright orange glow, use the air to trigger and blow out more oxygen. Bolt would then start to meltdown.

Turn your torch off and quickly hammer the threaded side of the flange bolt. Repeat the process until the bolt is out of the exhaust.

Let the hot bolt cool down for around thirty minutes. Make sure no combustible materials are lying around before you leave the area.

Throw the cut bolts after another hour or two to ensure that the bolts are at room temperature and won’t cause fires in the garbage bin.


If the problem persists and it becomes impossible to remove the exhaust flange bolts, it is better to consult professionals. Contact your local supplier for more information.

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