Tools for rounded/ rusty fasteners

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A Dremel with the big 1 1/2" "EZ Lock" cutoff wheels that snap into the quick release arbor are good. Still takes time but doable. The arbor is spring loaded so the wheel won't break if you don't hold it correctly. Good for tight spots. I cut through one exhaust flange NUT and bolt with one wheel.
 
They finally came in. Looks like they’re impact rated too, which I initially missed. This one has an 18mm too. Bought it on eBay.
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A Dremel with the big 1 1/2" "EZ Lock" cutoff wheels that snap into the quick release arbor are good. Still takes time but doable. The arbor is spring loaded so the wheel won't break if you don't hold it correctly. Good for tight spots. I cut through one exhaust flange NUT and bolt with one wheel.

I had the best dremel they sold with one of those wheels and tried to cut lengthwise down a corroded expansion valve, the thing got hot as Hades and let the smoke out before the plastic caught fire. LOL
I have no idea why I don't throw the mostly worn down 3" wheels out but a half used one on an air cutoff wheel did the job albeit a bit hairy to do.
 
In general I have found Vise Grips do a miserable job without heat. I have a small pipe wrench (6 inch, 10 inch maybe?) that works 100% better than Vise Grips for grabbing and holding nasty fasteners. The harder you push the tighter it bites.
 
I've done that as well. I want a small smoke wrench set, but i'm propped up a propane torch on a bolt, had a cup of coffee while it heated, the hit it with the air cat. I have a 13mm scar on my arm where a red hot exhaust nut landed after heating and the aircat zipped it right off.
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This is why mechanics wear coveralls, not t-shirts and shorts.
 
cut them off + replace with 300 series stainless band clamps, no rust EVER!! of course cheeper 400 series OE exhaust corrodes, + as noted liquid wrench- cutting torch is fast + EZE
 
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