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Re: Exhaust options: Swapping Intermediate Pipe for CAT?!
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Posted by adamK (more from adamK) on Wed, 28 Feb 2007 10:05:29 Share Post by Email
In Reply to: Exhaust options: Swapping Intermediate Pipe for CAT?!, Daven [Profile/Gallery] , Tue, 27 Feb 2007 13:45:07
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I'm not sure if the flexpipe is the same way, but I just finished repairing the rear muffler section on my '96 Aero. The welds at the flange on each end of the pipe were pretty crispy, but the rest of the pipe was great. What I did was measure exactly 1 foot from the end of the flange, and mark the pipe, labeling it ' 12 inches '. I did that on each end, then cut the pipe back far enough to get into good, weldable meat.

From thereI put the removed pipe and flange into a vise with the pipe sticking up in the air, and using a grinder, I ground down the pipe and factory weld until it was smooth with the flange. While grinding, I noticed that a dark ring was starting to show as I ground down further.

Once I was done grinding, I realized that the ring was where the actual pipe met the flange, before it was welded. I flipped the flange over in the vise and using a screwdriver with a hammer, removed the exhaust pipe from the flange. What you are left with is JUST the flange, ready to accept 2.25" ID exhaust pipe! Take your new pipe (after cleaning up the mating surfaces as well as you can), insert it into the flange and weld it.

I suggest taking that flex pipe, even if its rotten, and doing what I did; remove the pipe from the flange, then from a parts store, get the exact length of 2.25" ID tubing you need and weld the flanges on. It should only be a few bucks in tube. From start to finish on that center section, I was into it for a pair of 4" adapters and some grinding time. Saved $180+ using this method.

-adam

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