Large Gap in the Exhaust Pipe to the Intermediate Pipe

[globochem]

Working on a 1985 Brat, I had a huge exhaust leak at the connection between the exhaust pipe after the converter to the intermediate pipe before the resonator, so I figured I'd replace the gasket and also try to address the sag in the exhaust system which probably caused the leak in the first place.

I inserted the gasket (Fel-Pro 60566) and bolted the pipes back together but this just seems like too big of a gap. This model number is supposed to fit an '85 Brat but it just doesn't seem like the tightest seal to me. I'm new to this so maybe I'm missing something but does this look right?

Driver side angle: https://drive.google.com/file/d/105GyNzLpYFJoks3KG9s_aT19iXtZzf50/view?usp=sharing

Passenger side angle: https://drive.google.com/file/d/1t7cSIzs9kHmFQHRBTQv4jEOzX9f-xZnl/view?usp=sharing

Additionally, where are the exhaust hangers supposed to be on the frame? I'm only seeing one near the rear axle. I don't know if the others rusted off or what but someone before me just wrapped a piece of wire around the pipe and the sway bar: https://drive.google.com/file/d/11u0OvjgNDVYK-dmv_C4Y7_S13niNH4HD/view?usp=sharing

Thanks for any tips.

[bushytails]

That looks right to me.  The "gap" will shrink as the donut wears.  There should be a bracket on the back of the transmission that the exhaust rigidly bolts to, not a hanger.  This is a little newer, but shows how it works:  https://www.subaruoutback.org/attachments/560913/

[globochem]

Man, I'm just not seeing it if it's there. I can see on the exhaust pipe where the bolts would attach to a bracket, you can see it in the first image, but I don't see where the bracket would attach to anything. I'm wondering if the bracket rusted off at some point and this sheared area is what's left: https://drive.google.com/file/d/11zdb1sjc_dODNp6YoLSoJigjvWzudY8K/view?usp=sharing

Google Image Search has some nice shots of the underside but I haven't seen anything with high enough resolution to really see what's going on.

Thanks for the insight on the donut, that makes sense.

[bushytails]

Here's two pics of an extremely mushed 4-speed d/r one, and a non-mushed 5-speed d/r + ej car:  https://imgur.com/a/bUgpkRj

I'm guessing your bracket is missing, if there's nothing like it hanging down. 

[globochem]

That's super helpful, thank you. I feel like I'm close to solving this mystery. In that first image is there one or two bolts that attach to the transmission? Do you know what size they are?

Another forum presented this parts chart: https://imgur.com/qu43AD3

Based on what I'm seeing on the transmission and the images it seems like it'd be No. 4 but if I'm reading that right it's for an Automatic and I've got a 4WD Manual.

[bushytails]

Since you're probably going to be fabricating your own, just make it fit whatever bolts you want.

 

[globochem]

Thanks for walking me through the mounting bracket location, I was making it way harder than it needs to be and I think I've got that situated.

I'm still having a problem with the exhaust where the pipes meet, though. I've got a brand new gasket in there but it's leaking in the same way that it did before I changed the gasket. I don't see an issue with the pipes like a crack or hole, so I'm thinking it has to be the connection. Does anyone know the correct size of the bolt/spring set that joins the flanges together or does it not matter as long as there is a secure connection?

[bushytails]

As long as the springs are holding it tight, it doesn't matter what they are.  My car has generic dorman ones from the auto parts store.  Did you make a new bracket?

[globochem]

As a temporary measure I just got a universal bracket to hold the pipe in place.

I'm still having trouble with my exhaust, though. I've been able to attach the hanger, which helped with the sag in the connection, I replaced the gasket and the bolt set.

I don't see any holes on the pipe but after the engine is running for about 90 seconds there's a smoke that comes off the pipe around the flange. It looks like the smoke is radiating from the pipe just before the flange on the manifold side. I tried using soapy water to see if I could find any bubbles but I'm not seeing anything.

It doesn't seem like it's an oil or any other sort of liquid that's burning off because it's always done this since I got the car a couple months ago. If there was any residue I figured it'd have burned off by now, especially after I've wiped it down. There's no smoke coming out the tail pipe, it's just around that connection between the exhaust to intermediate pipes.

Any suggestions of what to look for? I've been using a thermometer and it doesn't seem like anything is overheating, everything is in range as far as I can tell.

https://drive.google.com/file/d/15sDwiU7-1OyZq7SzNpBhi5cRXYKuRaKj/view?usp=sharing

edit: and one other thing instead of starting a new thread... Apparently the transmission is supposed to be grounded and I've got this black wire just hanging loose. I'm wondering if this is the ground wire and if it's supposed to ground to this spot since it seems to be just the right length: https://drive.google.com/file/d/166thpiZb3AhqsFjT47-IHUJOek_bpj4j/view?usp=sharing

Edited July 11 by globochem

[88SubGL]

Have you taken this thing to a muffler shop and let them take a look at it? They’re probably going to be in the position to tell you what’s going on.