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-   -   Replacing full exhaust downpipe(+flex) vs cutting in new flex pipe? (http://www.saturnfans.com/forums/showthread.php?t=231632)

EvanVanVan 06-28-2017 07:30 AM

Replacing full exhaust downpipe(+flex) vs cutting in new flex pipe?
 
2 Attachment(s)
I was changing my oil yesterday when I noticed holes in the exhaust pipe at bracket before the flex pipe. The braiding has also completely broken free and had slid off of the flex part. I see that holes are pretty common at that spot.

I'm wondering if it's preferable to cut out the flex pipe and replace just that part, or to replace the whole downpipe and only be forced to couple/weld once right in front of the cat instead of having to seal two spots on either side of the flex pipe? Also worried that any weld/coupling in front of the flex pipe will hinder replacing the front clamp/bracket.

FWIW, I'm thinking of just using Permatex muffler sealer and a clamp to temporarily/permanently-as-long-as-it-lasts put this exhaust pipe back together instead of finding someplace to weld it. I'm probably getting a new car in the next year or so, lol I just hope it lasts until then...


Also, I attached pictures of the sensor wires that look like they're no longer attached properly (the plastic clips seem to have broken). Does anyone have pictures of where the wires are supposed to be secured?

Thank you

fetchitfido 06-28-2017 07:49 AM

Re: Replacing full exhaust downpipe(+flex) vs cutting in new flex pipe?
 
With 3rd gens (well, '99+) the only reliable fix is to cut out the bad section and weld in new pipe. Nobody aftermarket has reliably gotten the manifold flange height/angle and downpipe bend angle even close to correct like they have for '91-'98's.

New flex pipe = under $20
Welding = ~$50

after looking at the pictures:
I'd try to find someone with a welder to just fill in the holes around the clamp. Can't see how bad the flex pipe is but the exterior metal mesh isn't part of what seals up the exhaust in that section.

EvanVanVan 06-28-2017 08:08 AM

Re: Replacing full exhaust downpipe(+flex) vs cutting in new flex pipe?
 
Thank you, yeah my first thought was just have some one weld the holes but then when I saw the walker new flex pipe I figured that'd be the better fix. But hearing (and seeing in Richpin's video) how difficult it is to weld the top of the front joint idk if I trust someone to do it properly/fully. I'm going to take another look at the flex pipe beneath the braid and will take pictures.

Another thought I had, about about [I]a lot[/I] of Permatex sealer and [I]a lot[/I] of rivets around the entire thing? I heard the rivets could loosen up over time, but I feel like it should last a while if I get enough of them in there to truly keep it form vibrating.

And oh yeah, the Amazon reviews did say the Walker downpipe had to be cut re-welded to work on 3rd gens, I forgot about that. Thanks

PeterT 06-28-2017 03:46 PM

Re: Replacing full exhaust downpipe(+flex) vs cutting in new flex pipe?
 
Yeah, on my 99 sc2 w/275000 on it. I had from manifold exhaust back redone, and am having codes come up now Po404. When a vehicle gets so old, get ready to replace lots of parts. Hope to not break down in middle of street

PeterT 06-28-2017 03:51 PM

Re: Replacing full exhaust downpipe(+flex) vs cutting in new flex pipe?
 
But, omg my new glasspack, etc is badA

bumpdraft 06-28-2017 04:12 PM

Re: Replacing full exhaust downpipe(+flex) vs cutting in new flex pipe?
 
EvanVanVan, Paint your oil pan soon. They are not that thick. Without paint, you will soon see drips on the driveway.

Kaervak 06-28-2017 06:33 PM

Re: Replacing full exhaust downpipe(+flex) vs cutting in new flex pipe?
 
[QUOTE=fetchitfido;2246032]With 3rd gens (well, '99+) the only reliable fix is to cut out the bad section and weld in new pipe. Nobody aftermarket has reliably gotten the manifold flange height/angle and downpipe bend angle even close to correct like they have for '91-'98's.

New flex pipe = under $20
Welding = ~$50

after looking at the pictures:
I'd try to find someone with a welder to just fill in the holes around the clamp. Can't see how bad the flex pipe is but the exterior metal mesh isn't part of what seals up the exhaust in that section.[/QUOTE]

That's not entirely true. My 99 SL2 with a build date of 6-19-99 has a Bosal 0795190 down pipe and catalytic converter on it and it fits perfectly. There are no clearance issues with hitting the subframe or transmission and the flange is welded on with the correct angle.

Jonasan308 06-28-2017 07:04 PM

Re: Replacing full exhaust downpipe(+flex) vs cutting in new flex pipe?
 
[QUOTE=bumpdraft;2246079]EvanVanVan, Paint your oil pan soon. They are not that thick. Without paint, you will soon see drips on the driveway.[/QUOTE]

I take it they get rotted through from rust and then weep oil?
What kind of paint would be used to protect it?

EvanVanVan 06-28-2017 07:04 PM

Re: Replacing full exhaust downpipe(+flex) vs cutting in new flex pipe?
 
Any thoughts on riveting the pipe as a temporary-permanent fix? I would just use the standard aluminum ones.

[QUOTE=bumpdraft;2246079]EvanVanVan, Paint your oil pan soon. They are not that thick. Without paint, you will soon see drips on the driveway.[/QUOTE]

Yeah, I was wondering about that...thanks for the tip!

bumpdraft 06-28-2017 10:04 PM

Re: Replacing full exhaust downpipe(+flex) vs cutting in new flex pipe?
 
[QUOTE=Jonasan308;2246094]I take it they get rotted through from rust and then weep oil?
What kind of paint would be used to protect it?[/QUOTE]

I apologize for the off-topic...
Por15 is the best. It is expensive. I found the "6-pack black" to be to most economical.
Here's an old pan...Rustoleum will need to be touched-up: [url=http://www.saturnfans.com/photos/showphoto.php?photo=57209][img]http://www.saturnfans.com/photos/data/13558/thumbs/OilPanRust.JPG[/img][/url] It rusted thru. Note the sheetmetal screw and faucet washer.
This is the inside of the [I]same pan[/I] (pictured above). It rusted thru from the outside. Note the sheetmetal screw:[url=http://www.saturnfans.com/photos/showphoto.php?photo=57210][img]http://www.saturnfans.com/photos/data/13558/thumbs/OilPanHole.JPG[/img][/url]

trottida 06-29-2017 07:52 AM

Re: Replacing full exhaust downpipe(+flex) vs cutting in new flex pipe?
 
+1 on the POR-15. I did this to my oil pan on my [URL="http://www.saturnfans.com/forums/showthread.php?t=219810"]99 SL2 project[/URL] which had a pin hole due to rust. I embedded a patch of fiberglass mat into the POR-15 and added a few more coats over top. It worked like a charm. There are photos in [URL="http://www.saturnfans.com/forums/showpost.php?p=2221587&postcount=134"]post 134 of my thread[/URL].


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