- Messages
- 36
time to blow the dust off my thread .
got myself a proper exhaust
BUT if you think it was a bolt on job, you'd be wrong..
I've known about the cat flange issue and sorted the holes with an angle grinder so I could bolt the exhaust to the cat.
But as soon as I've alighned the pipe to the cat i noticed that the cat flange barely even covers the pipe, so there was a high chance that I would have an exhaust leak. Nevertheless I started bolting the exhaust on to see how it sits. And as i've tightened the bolts the whole midsection was touching the floor of the car :x . So we took the cat off and cut it right behind the flange, mounted it back on, bolted the exhaust on and pulled a bit on the exhaust to bend the flange so the pipe would have more clearance. Everything back down again and welded the cat with the repositioned flange and welded some material on the sides of the flange and grinded it flat so it would seal better. Everthing back up again and it looked alright with just some clearence between the exhaust and the floor of the car.
Went for a quick drive and noticed an exhaust leak between the header and the cat and also the now hot exhaust was touching the floor with the second flange, but it was ok when cold. But we ran out of time for that day.
So the next day I went to a local exhaust shop to get it fixed.
We ended up cutting the second flanges off and welding the pipe directly to get more ground and floor clearance. And by closer inspection noticed that the exhaust is a couple of cm too far back and when it got hot and therefore longer it touched the lower control arm, burning the protective plastic a bit. And I didn't like it sticking so far out anyways. Also the manifold to cat leak got fixed with a new gasket.
It's still quite low, but it somehow clears speedbumps even with four people inside.
Please, don't be disgusted about my massacre with the cat converter, it will get replaced with a proper header in no time.
Also, I've replaced the auto tensioner with an SKF one. The old one was not moving smoothly.
Will upload some better photos when the weather clears
got myself a proper exhaust
BUT if you think it was a bolt on job, you'd be wrong..
I've known about the cat flange issue and sorted the holes with an angle grinder so I could bolt the exhaust to the cat.
But as soon as I've alighned the pipe to the cat i noticed that the cat flange barely even covers the pipe, so there was a high chance that I would have an exhaust leak. Nevertheless I started bolting the exhaust on to see how it sits. And as i've tightened the bolts the whole midsection was touching the floor of the car :x . So we took the cat off and cut it right behind the flange, mounted it back on, bolted the exhaust on and pulled a bit on the exhaust to bend the flange so the pipe would have more clearance. Everything back down again and welded the cat with the repositioned flange and welded some material on the sides of the flange and grinded it flat so it would seal better. Everthing back up again and it looked alright with just some clearence between the exhaust and the floor of the car.
Went for a quick drive and noticed an exhaust leak between the header and the cat and also the now hot exhaust was touching the floor with the second flange, but it was ok when cold. But we ran out of time for that day.
So the next day I went to a local exhaust shop to get it fixed.
We ended up cutting the second flanges off and welding the pipe directly to get more ground and floor clearance. And by closer inspection noticed that the exhaust is a couple of cm too far back and when it got hot and therefore longer it touched the lower control arm, burning the protective plastic a bit. And I didn't like it sticking so far out anyways. Also the manifold to cat leak got fixed with a new gasket.
It's still quite low, but it somehow clears speedbumps even with four people inside.
Please, don't be disgusted about my massacre with the cat converter, it will get replaced with a proper header in no time.
Also, I've replaced the auto tensioner with an SKF one. The old one was not moving smoothly.
Will upload some better photos when the weather clears
Last edited by a moderator: