So, I'm trying to removing the nuts and the converter studs for a couple weeks. I've been consistently applying naval jelly and cleaning off the rust for a couple weeks.

Today I took a picture (about 8 or 9th application?) and I can finally see bare metal of both flanges and the lower left stud. Only one stud appears to have a nut on it (This is common?) and the metals fused together. If I cut off the end of the studs, should I be able to remove them? I figure if there's any rust in there I can just apply more naval jelly and get it out. Can rust fuse metals together?

 

that really looks like a job for an exhaust shop .. i usually try to do all my own work but thats really asking too much for a diy-er

 

That connection on my TSX recently came apart. Only one stud was able to hold a bolt, and i used that to hold it together until I had time to fix it. The other two studs were toast.

I was able to knock out all three studs, but this is a job that certainly has the potential to be a nightmare.

I'd suggest getting a quote to replace the flange at an exhaust shop. I'd probably not have those two pipes welded together. Or wait until you have either an exhaust leak or the exhaust comes apart.

 

Well, I cut off the two lower stud and nuts yesterday. The bright side is when I cut them off I could see more rust, so I applied some naval jelly in there and I'm hoping they work themselves loose.

A cut off wheel made quick work of the job.

What are my options if a hammer & punch won't drive the studs out?

 

Looks like a mess to me..Exhaust shop would be my choice .

 

Heat. An oxy/acetylene torch if you have access to one but even a propane torch should do it. Heat the flange and drive the studs out with the punch.

 

All I needed was a 2 lb hammer. Took maybe 5 good hits on each stud to knock them out.