Rust...Tips? Tricks? Anyone?

[Dweano]

I'm trying to put on headers and failing hard core. The y pipe catalytic converter connecting bolts rounded off...time to whip out the grinder, which isn't really too bad. But trying to remove the EGR tube is a major PITA, I have to use open ended wrenches (look under your hood if you don't know what I'm taking about) and so far the wrenches just slip. Not too long down the line i'll have rounded them off. I haven't even begun the head bolts yet, to be honest I'm scared. I sprayed the EGR tube with penetrating oil daily for about a week, no apparent help. I've also sprayed the head bolts and praying that will have an effect. I used normal stuff and the freeze so the rust cracks and penetrating oil gets in blah blah stuff. I figured why not. Also I think i heard that in impact wrench works good. Any other words of advice for getting stuff unstuck? Not only for headers, because many a time I have had this problem.
P.S. What size are head bolts, 3/8 is too small, 7/16 is too big? 11mm too big, 10mm kinda too big, 9mm too small???? Are mine messed up or do i need something special. Damn you header project...

 

[adsm08]

vice grips. big, ugly vice grips.

also, they probably are a 9 or a 10 but the rust has distorted them, if 10 slips, get out your 2lb hammer and tap the 9mm gently into the head. Most manifold bolts that I'm familiar with are 12mm.

 

[Bondo]

Walk the heat to them with a torch, it helps alot.

 

[Dweano]

Thanks guys, my boss (was an industrial mechanic pretty much told me the same) and Bondo what do you mean walk the heat to them? Heat around and get closer and closer?

 

[JohnnyO]

Somebody posted not too long ago about an experiment that showed a 50/50 mix of ATF and acetone worked better than any penetrating oil. I haven't had the need to try it yet myself but it's worth a shot.

 

[Dweano]

Hmm...acetone and ATF...I may have to try that. I wonder who and how they figured that out haha