Coned O2 Sensor Nuts

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Joined
Jul 25, 2021
Threads
13
Messages
180
Location
Toronto, ON
Hey gang, ive tried everything in the book at trying to get these o2 sensor nuts off. The nuts are so rusted they are coned off at an 45 degree angle. I used an angle grinder and accidentally cut abit of the bolt off and the nut seems to be completely fused together with the bolt from the exposed bits that I cut off. So far I've tried, pb blaster, nut extractors (which just shreds the out side of the nuts off), hammer chisel, nut splitter (no space), angle grinder (no space), vice grips (shreds outside of the nuts off and can't really grip given the coned angle)..I will give my air hammer and oscillation tool ago, but I am not sure those will work either.

What is the last resort? go to an exhaust shop and remove the two sections of piping and weld on new section with welded O2 sensor?
 
slee offers a replacement bung if it gets to that point…

 
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