RMCSMat

Thanks everybody.. I went in to the hobby shop and put it up on a lift and did some more cleaning. There really wasn't much more to get off. The big difference was the OEM parts vs the "compatible" parts purchased at NAPA. Absolutely not the same. Not only did the bolts have 2x the thread, the gasket itself was smaller and fit into the concave area much better. I still ended up with 1 added washer to add a little extra tension to the spring. But, at least no leaks this time. No headaches and tight chest. Wife likes that. I noticed my next two projects while I was under there. I think I'm missing some protection or skid plates from up front. and also I noticed that every blasted screw and nut attaching the exhaust shroud parts on are rusting away. Obviously made of the wrong material. I'll have to bust every one of them off and replace them. Is that how Subaru guarantees return visits or did I get had by a cheap shade tree mechanic. Disappointed. Thanks for the help all! Curt

Fairtax4me.... Thanks for posting the pics, it's so much easier. I appreciate that. You're right on with the thread size, wow what a difference. There's probably 2x the threads on the OE kit pictured. I just went with what I could find locally. I do have a Subaru dealer local, I'll try and get a new set from them. I'm going to try to get in to the hobby shop and put this thing on a lift Saturday and wire wheel it cleaner. I wonder what the reason is for the shoulder on the bolt. If I got a SS bolt and washers and tightened it down until the spring was compressed, wouldn't that work as well?? I could really cinch it down then. I'll see what the Subaru dealer has for this wk end. Thanks for the help.

Thanks for the reply Rooster2. I just picked the part from a parts line up. No choice on size. And you're right on with the Haynes point. "shallow and generic"?? how bout non existent! They don't even deal with this union. Oh well, that's why I have the USMB!

Here are three pics. You can see the washers I added. and how much of the gasket shows and the gap between the flanges. Thanks for the help http://picasaweb.google.com/108176592055780494090/BajaExhaust?authkey=Gv1sRgCM2Oi93z74X9Pg# Curt

I'll try some pics. I have to find someplace to put them, crap. stby Curt

Thanks GD, I spent an evening under it (again). Spent a lot of time cleaning both surfaces. The flat one wasn't to hard to clean, but I'm not sure it's completely flat. There is still a good amount of metal there. It's not thin or flimsy and doesn't show signs that it contacted the ground. I put it together again and after tightening the nuts all the way down, I could still see a lot of play as I flexed the pipe up and down. It just didn't seem like the springs had enough tension to hold the parts together. I added a couple of washers to bring the tension up. It's better but there is still a significant amount of exhaust gas leaking. Not sure what to try next. Maybe I can get it up on a lift and use a wire wheel to clean some more. I don't see how a spring connection like that stays gas tight. Curt

Substantial? Pray tell.... I didn't get it at the Subaru dealer, I got it at NAPA, so it probably qualifies as "after market". I'm a procedures guy. This is killin' me that there isn't anything in the book on this. Thanks Curt

I had a small leak at the union where the spring bolt kit is. I got the new bolts and a gasket. The hardware on the exhaust system is all badly corroded so I had to cut the old bolts. I found that there was no gasket. So I figured I was going to win this one. Well... I put the new gasket in. Flat side forward and the new bolts. Tightened the nuts about as much as I could with a short wrench. Started it up and .... leaks even worse. The Haynes manual I have doesn't address this repair. Is there a trick to installing this metallic gasket? Do I need to torque it? I intend to take it apart again tomorrow and see if there's a rust build up causing the gasket not to seat. Otherwise I guess I'll just get a bigger wrench and put more arm on it. Thanks for the help.. Curt