Need tips on removing and repairing rusted exhaust manifolds

[mad2smile]

I have a 390FE that has some pretty bad exhaust leaks from the manifolds.

the drivers side manifold is in decent shape and appears to have a good surface, but i want to replace the studs on the output side. i also want to make sure the doughnut has a good surface to seal against.

the passenger side manifold is a whole different story. it appears to be intact, but i've never had it off the engine due to rusted bolts, many of which are rounded off. in addition to this issue, the doughnut on the output side cannot seal because one of the studs is broken. i know that my local machine shop can handle resurfacing the manifold if necessary. i just need some advise on how to do the rest.

any tips on
(1) removing the rusted manifold bolts without breaking anything
(2) removing the output-side studs and prepping for replacement (again, without braking anything)
(3) coating the manifolds with some kind of paint (need product suggestions)

[fordman]

some methods for removing bolts are:
heat
pr blaster
wire brushing the threads if any are showing.
heat up the bolt and melt bees wax into or onto the threads.

to remove broken off studs and bolts:
vise gripps and one of the methods above if you can get vise grips on it.
drill out the bolt or stud.

Clean all threads out with a tap when done. plus use any kind of antiseize you can.

The only paint i know of is bbq paint and high heat engine paint.

broken bolts and studs are a pain in the ace. i have two messed up ones right now myself. i am waiting until i can gather the patience to deal with them.