gregB Posted May 1, 2011 Share Posted May 1, 2011 My rear Cat pipe cracked, just before state inspection Before I spend money, has anyone had any sucess welding up the crack? I have a Mig, but have never tried anything this thin. Not even sure anymore in PA if you are allowed to weld an exhaust to repair. Thoughts? Greg Quote Link to comment Share on other sites More sharing options...
davebugs Posted May 1, 2011 Share Posted May 1, 2011 I replied to your other thread as well. Find an INDEPENDENT exhaust shop that bends pipe. My local place charges me 40 bucks to cut out the flex joint, make a sleeve, and weld it in. Makes all the sense in the world to do it this way versus buying a bunch of parts and the repair still not being optimal. Quote Link to comment Share on other sites More sharing options...
logic23 Posted May 2, 2011 Share Posted May 2, 2011 have the flex joint cut out and the flange between the muffler and straight pipe.. your exhaust will last along time. I have seen several with 200,+++ miles with the original pipes etc. Quote Link to comment Share on other sites More sharing options...
gregB Posted May 2, 2011 Author Share Posted May 2, 2011 I crawled under the car finally. The spring bolted "doughnut" seal collar clamp has rusted and pulled off the rear outlet of the cat where it is flanged. Can this be repaired by parts replacement, Or do I need to see a specialist? Quote Link to comment Share on other sites More sharing options...
subaru360 Posted May 3, 2011 Share Posted May 3, 2011 You just need to pick up a split flange from autozone and a new donut gasket from the dealer. They all break there. There is almost always enough left for a split flange to grab. Use the bolts that come with the split flange and forget the spring bolts. Quote Link to comment Share on other sites More sharing options...
gregB Posted May 3, 2011 Author Share Posted May 3, 2011 That what I figured after I started web trolling. Is there any reason not to also get the dounut gasket from Autozone or Advance? Thanks Greg Quote Link to comment Share on other sites More sharing options...
davebugs Posted May 3, 2011 Share Posted May 3, 2011 That what I figured after I started web trolling. Is there any reason not to also get the dounut gasket from Autozone or Advance? Thanks Greg Walker makes the donut I know. But seriousely I'd get it welded. By the time you buy 2 flange kits, some extra bolts (to pull the flange kits together), the donut and some rather unpleasant work for only a "passable" repair just having it welded is good money spent. You should be able to search for my user name and "independent" to see some other recent folks experiences. Yes everyones repair need is different, they value their time differently, etc. So there is no clear cut choice, but I heavily favor having a shop with the correct tools do it in about 15 minutes for 40 bucks. Quote Link to comment Share on other sites More sharing options...
subaru360 Posted May 3, 2011 Share Posted May 3, 2011 That what I figured after I started web trolling. Is there any reason not to also get the dounut gasket from Autozone or Advance? Thanks Greg The parts places don't stock them and they don't fit right when they get them. For some reason only the factory one fits right. It'll hold up for a long time, ones I did a few years ago are still leak free. Quote Link to comment Share on other sites More sharing options...
987687 Posted May 3, 2011 Share Posted May 3, 2011 The parts places don't stock them and they don't fit right when they get them. For some reason only the factory one fits right. It'll hold up for a long time, ones I did a few years ago are still leak free. This. I went back to napa 4 times with the wrong doughnut gaskets. Either didn't fit or leaked. Finally made the drive to the dealer and the gasket was perfect. Quote Link to comment Share on other sites More sharing options...
gregB Posted May 20, 2011 Author Share Posted May 20, 2011 Finally went to the indy exhaust place a co-worker recommended. $40 he put in a welded sleeve, and welded up a large crack on the inlet side of the rear cat. Got my yearly sticker without spending big bucks on a replacement cat. thanks guys Any chance this would also improve the gas mileage, as I am no longer drawing in a little excess air in front of the rear o2 sensor? Quote Link to comment Share on other sites More sharing options...
davebugs Posted May 21, 2011 Share Posted May 21, 2011 Doubt it'll help mileage. Aren't you glad you asked here for advice? Saved an expensive repair. Quote Link to comment Share on other sites More sharing options...
idosubaru Posted May 21, 2011 Share Posted May 21, 2011 Any chance this would also improve the gas mileage, as I am no longer drawing in a little excess air in front of the rear o2 sensor?no, rear O2 has nothing to do with gas mileage. disconnect it completely and you'll notice no difference. it's only the fronts that actually are used by the ECU for air fuel ratio monitoring. mine broke as well recently in my 96 LSi. i pulled it off and welded new pipe to the flange after cutting off all the old pipe and welded that to the converter. the rest of my pipe looks decent so it was worth it (hopefully). i replaced a friends about a year and a half ago and it quickly rusted terribly. a friend has his Audi similarly welded up (since parts cost as much as a house on those things) and it didn't even last a year. so - i painted mine up fairly well with high temperature automotive paint hopeing that might stave off the rust. might want to have a look at yours in a year and see if that cheap metal sleeve they installed holds up to the elements. i just used generic pipe fromt he store so i'll be checking mine as well. Quote Link to comment Share on other sites More sharing options...
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