1991 740 exhaust replacement

[JimG63]

I thought I'd bring my post from this morning over to a new post specific to what I'm working on.

I'm in the process of trying to get this car road ready for my daughter and the exhaust is shot, but I haven't had much opportunity to do much with the car. I got it home finally a few weeks ago and it's pretty much sat until yesterday when I began to tackle the exhaust.....all I can say is that in 100 plus years of the auto industry, you'd think they'd come up with a better way to attach an engine pipe to a manifold, other than rust prone studs and nuts....I have the entire exhaust off of the car except the last 6-8 inches of the front pipe. Had to break off the heat shield and made a cut with the sawzall up as high as I could. Most of the work was easy, just chopping up the exhaust in sections with the sawzall. I managed to get ONE nut off of the engine pipe flange, had to grind away most of nuts 2&3 with my dremel, got one chiseled off and the most poorly located one (it's always that one, isn't it) is giving me problems. Have to finish the last nut (started to rain) then hope I can remove the studs without snapping any of them. (soaking with PB Blaster from above) I'm awaiting the UPS man today with the Cat and engine pipe and new studs and nuts. Off to NAPA at lunch today hoping they have the O2 sensor.

Tools used so far include:
*Sawzall for chopping up the old system to remove it
*Dremel tool with flex shaft attachment for cutting the frozen nuts off of the studs at the engine pipe/manifold joint.
*A LONG cold chisel and hammer to complete the removal of the nuts. The longest I could find at the box store was 12" long, 14" would have been better.

Now, has anybody had issues with the hangers made by Starla? My rear muffler bracket has one hanger going forward and the other going backwards......and they don't line up with the car brackets.....