I am working on the exhaust on my car and found that the flange bolts are seized like mad. I've tried heating it up and using a wrench but no luck. I'm tempting to cut the bolt off all together (will not be keeping) and hitting the rest out with a pick and hammer. Any suggestions? If I do cut the bolt, will it all come out with some taps?
It depends on how the bolt is made. If it's threaded along the entire length of the stud, you're just going to make it that much more difficult to get out.
Heat the surrounding metal, not just the bolt itself and really heat it. It took an acetylene torch to heat the bolts in my Ranger's suspension to get stuck bolts out. Did you try to drench it in penetrating oil and let it soak? Use Liquid Wrench or PB Blaster and be patient. Put it in so gravity will pull it down through the threads if possible. Don't heat it up if you've applied oil recently, and don't apply oil to hot metal.
I used Mapp Gas torch to heat it. The bolts are pretty rounded. Could I just use drill bits to drill the bolt out after cutting?
A pair of vise-grips will grab onto a rounded off bolt head. Give the bolt some heat, make the vise grips grab the bolt head as tight as you can and give it a whack with a heavy hammer. It'll come out. I had a seized brake line in my 42 year old Pontiac and got it out this way.
Grab the head with the vise grips and what do I do with the nut? Or is that after cutting the bolt?
Can you see the nut, or is the part it runs through threaded?
I can see the nut
Just cut it off and replace with new
And it’ll come out with ease?
Nothing easy about rust