Exhaust removal - confused, How do I get this sucker off? Options

[ThePaintedMan]

Hello all,
I've been meaning to look for an exhaust leak at the head for some time. I ordered new copper rings, but before I can install them, I need your advice on how to get the exhaust off. As you can see in pictures, the headers have been so boogered up, that it is impossible to fit a socket on some of the barrel nuts. Its like the whole thing has been bent sideways, which means the header is butted up against the barrel nut. One of them in particular is really an issue because for whatever reason I cannot reach the top of the stud. The barrel nut is so far down along the thread that there is nothing sticking out far enough to get a socket on. To make matters worse, while tinkering with it, I backed one of the barrel nuts off only to find the stud pulled completely out. Is it possible to insert a helicoil with the engine in the car once I get the exhaust off? Thanks for the help!

[ThePaintedMan]

Great replies again guys.
My dad has a time-sert kit from his VW bus days that he is bringing down this weekend. He said that he did it with the engine in the bus before, and if my dad can figure it out, ANYONE can (IMG:style_emoticons/default/smile.gif) I'm not scared, its a learning process anyway. I'll look into finding the correct nuts when I talk to John at Aircooled.net this week.

I did try prying the header over, but with all the horror stories about how delicate the heads are, I went pretty easy on it. Couldn't get enough movement to make much of a difference. Might end up going the cutting route after all. Anyone have an old used 1.7 exhaust lying around they want to get rid of?

As far as shops go - you guys are truly blessed out in California. No one in this part of Florida touches air cooled cars, or at least no one I've heard of that I'd trust. There is a VW buggy shop in Tampa with a great reputation but the last time I stopped in to ask them for advice they basically told me to take a hike. That is what is most frustrating honestly - that a younger person wants to learn about these cars but no one seems to want to share any knowledge. Thats why I'm here.

[walterolin]

Great replies again guys.
My dad has a time-sert kit from his VW bus days that he is bringing down this weekend. He said that he did it with the engine in the bus before, and if my dad can figure it out, ANYONE can (IMG:style_emoticons/default/smile.gif) I'm not scared, its a learning process anyway. I'll look into finding the correct nuts when I talk to John at Aircooled.net this week.

I did try prying the header over, but with all the horror stories about how delicate the heads are, I went pretty easy on it. Couldn't get enough movement to make much of a difference. Might end up going the cutting route after all. Anyone have an old used 1.7 exhaust lying around they want to get rid of?

As far as shops go - you guys are truly blessed out in California. No one in this part of Florida touches air cooled cars, or at least no one I've heard of that I'd trust. There is a VW buggy shop in Tampa with a great reputation but the last time I stopped in to ask them for advice they basically told me to take a hike. That is what is most frustrating honestly - that a younger person wants to learn about these cars but no one seems to want to share any knowledge. Thats why I'm here.

PaintedMan, I have a set of 1.7 pipes, no sheet metal, here in Louisville which you can have. I will even deliver, but you might have to wait for a month or two.

Our daughter lives in Meadowlawn and we are coming down sometime in the next few months.