Rusted exhaust flange

[djp5]

Just got a 2002 p5 a month ago and I want to put on the MazdaSport axleback....
...but I looked at my bolts and they are pretty badly rusted. In fact, the pipe flange and muffler flange are both pretty rusted.

Could I pull off putting the axleback on even with the rusty flange? I'm probably going to have a shop cut the bolts because I don't have any tools to do it. I didn't want to have to pay for a full catback, but do you think I will have to, given the condition of my midpipe?

[Rogue]

wow..that's a lot of rust. Where do you live? Up in the "rust belt"? Looks like you have rust on the suspension component, too.

[djp5]

yeah, I live in Ohio. Not sure if it was stored indoors or out by the previous owner

[p5power]

geeze...this looks familiar. i was just under my car changing the oil last weekend and noticed this too. i actually think mine is more significant...stupid winter. i can't believe how much rust my car has for being just over 2 years old. i guess mazdas weren't designed with winter weather in mind.

[rit14623]

The rusty flange won't be a problem. It is a solid chunk of metal. The mid-pipe will rust through before the flange will become a source of a problem.
You should look over the mid-pipe. If it's rusting through, you may want to get a full cat-back system.

[mogi]

soak that biatch in a bunch of PB Blaster, a couple times over, and I bet the bolts come out pretty easily.

[Action Jackson]

Mogi's got the right idea.

I would also try to scrap off most of that rust with a wire brush.

You might also want to get a set of extra bolts just in case.

Hope you have the gasket for that axleback b/c you cannot use the stock one.

[PrOhioStateEge5]

Too bad you dont have access to a sabre saw or Sawzall. Thats how I got my stocker off. I too live in Ohio and rust around here is a biatch.

[djp5]

My concern is that if I go at it with a saw that the flange itself might be so rusted/damaged that I couldn't put another muffler on it and seal it well. Any thoughts on that? Thanks!

[mogi]

like I said, PB Blaster...

[doctormike]

save some more money and get a cat back system......it's worth it

[AceProtege]

try PB blaster first.....you will probably break the bolts when you try and loosen them. just get some now ones when you put the new exhaust on.....

you might just have to cut them off........thats what i had to do to remove mine......

north east really sucks.....you should see the bottom of my car after 3 years of living up here and parking outside.

[iLisa]

when I put the Sport Exhaust on mine, I was also very rusted on... took it to Merchants and had 'em torch it off.. of course they promised not guaranteeing anything.

[Nomad]

After you clean it all off you might want to look into stuff called rust bullet.

It's paint that halts rust formation and protects it.

Or you can clean off as much rust as possible and hit it with a nice high temp paint. That would at least give it a little protection.

On my Miata I have Jackson Racing Cat back and the flange is totally rusted now too. The pipes are ok but the bolts will have to be cut to get it off.

[2xsess]

Geez, you just made me NOT miss living up north for the first time in months. (PA native by birth)

[Captain KRM P5]

wow my 85 rx7 didn't have that much rust :(

[altspace]

That is serious rust action. I suggest that if you don't have the proper tools, don't try it. (ie. Long wrech or impact tools)