Exhaust Surprise - Heater Box Exhaust Outlets Welded

Two possibilities:

1.  cut off your old muffler and weld on the new one.

2.  cut off your old muffler and weld an extension pipe to the heater boxes or muffler so the clamp will have enough to attach to.

 You could unfold the lips on your old heater boxes and transplant them If the dont go togher perfect spot weld or brase up the cracks. i have done that,, it takes some time  But why not

You can get heat exchanger repair stubs and have them welded on.

 

http://www2.cip1.com/ProductDe...de=VWC-113-255-107-X

 

So the repair pipe has an outside diameter that is sized to fit inside of what remains of the exhaust outlet, and has and outside diameter at the opposite end that is the same as that of the heat box exhaust outlet?

Been few years since I did repair but I cut off the stub that came out of heat exchanger near to the outside tin collector.  Thn I tapped in the smaller end of the repair kit and brazed or welded it on.  The exhaust muffler piece slides in side the larger end if I recall.

 

A better fix might be to weld 2 bolt flanges between the 2 (one on each for total of 4).  Much easier to remove the exhaust that way as rust won't fuse the pipes together.  

Oops - On second thought the exhaust pipe goes over the big end.

What Wolfgang said x2. Flanged pipes for better connection and easier R&R.

 

Nice

My challenge is that I don't have a welder handy.  So I'm stuck with the prospect of sawing through the tubing, and then improvising to get the new exhaust system installed at least well enought to make it to a local muffler shop.

 

My thought is to make a first cut downstream from the weld in part of the old exhaust tubing just to get the old exhaust removed from the car, and then reevaluating a next cut location towards the heater box to got a best fit for the short drive to the muffler shop.

 

Looks like I am going to get to know my hack saw very well over the Christmas holiday. 

 

Grant

Just let muffler guys lop it off - they have air saws and air grinders and will have it done in a few minutes.  Not worth the shinned knuckles and rust in the eyes.

Yeah, I would just take it to a muffler shop, too.  What they could do in 15 minutes would take you a half to maybe a full day to do. My guess is they would get $100 to replace your header and weld flanges on.

Agree with the guys. Better get it done at a muffler shop; they'll do it right in no time and it will be cost effective; they do it all the time and have the expertise. Back when I installed the Tri-Mil from Kirk I had to weld flanges to the muffler to make it fit to the flanges on the performance heater boxes (1-1/2" diam. tubing). Luckily I had a longblock and engine stand handy which I took to the muffler shop (instead of my car) to get it done.