Stripped demon bolt, need idea

Robert Yuras

So, knowing that exhaust bolts are a pain, prior to even starting I soaked everything in PB and let it sit over night. Then sprayed it again in the morning. That evening got the drivers side knocked out in about 45 minutes. I thought "sweet, the passenger side will be a breeze in the morning" - what a dumb thing to think. I got the regular two bolts out immediately. Demon bolt turned two rotations with all my might and seized. So I the. Went from the front. I removed the intake box and used a 3 foot extension, slid it down and started pounding on it with my 1/2" impact - no avail. Eventually this all led to a rounded head. YES I was using 6 points. The bolt extractors did nothing for me. So I took a sawzall, and cut the cat out, by slicing up near the neck, just to get the piece of crap out of the way. I wish I'd done this originally.
I removed the other stud from the header flange and then used my 3' pry bar to bend the exhaust pipe flange back until the demon bolt was exposed.
Out came the grinder. Sliced through the bolt. *plop* done.
I quit. I'll put the res test pipe on this morning.