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Old 09-20-2007, 06:19 PM   #1
PCDTMurray
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1994 SL2
Default repair exhaust flange between cc & muffler

The bolts and part of the triangular flange rusted and let go. The pipes are in great shape, just the flange is shot. is there some type of repair kit? Maybe an oversized flange that you can put over the remains of the old one? The car has 218K on it and I would like to avoid replacing the cc & muffler. 1994 SL2

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Old 09-20-2007, 10:02 PM   #2
sl2clone
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Default Re: repair exhaust flange between cc & muffler

It's all stainless steel. Have an exhaust shop weld it together. Thats the best option. They can do it. Wether or not they will is another story. What area are you in if they rusted out so badly?

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Old 09-21-2007, 06:59 AM   #3
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Default Re: repair exhaust flange between cc & muffler

I'm in CT. It dosen't look like the flanges & bolts were stainless steel. The pipes definately, but this clamping hardware seems to be regular steel.

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Old 09-22-2007, 09:49 PM   #4
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Default Re: repair exhaust flange between cc & muffler

The bolts are actually studs with small heads. I am resurrecting another saturn right now. I hammered out the studs after burning the ends/rotted nuts off. If the flanges are shot , have the flanges cut off , they can slide a pipe in or over both peices and then weld it. If not then bring it to me. I can weld it. It's all a matter of if they want to fix it.
If just the nut ends rotted off , hammer the studs out of the converter flange. Heating them up will help so that you don't mangle and bend flange all to crap.

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Old 09-24-2007, 06:45 AM   #5
Sky King
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Default Re: repair exhaust flange between cc & muffler

Any good exhaust/muffler shop can weld it. In fact, I have found that unless you go with an OEM replacement converter, most replacements do not have a flange on it anyway. The muffler shop will cut the flange off the pipe and weld the new on in anyway unless you tell them not to.

I had a new converter put on my 95 SL-2 by a independent shop. They were going to cut the flange out but I ask them no to. Instead I had them cut AFTER the flange in front of the converter and weld the existing flange to the new converter. That way if I ever had to replace the down pipe, I could without having to cut and weld.

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Old 09-24-2007, 06:45 AM   #6
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Default Re: repair exhaust flange between cc & muffler

thanks for the reply. I ended up using a recip. saw to cut off the flanges and put in a short length of 2" pipe. Rather than going through the trouble of having it welded, I used a couple of U-bolt clamps. Have just a hint of extra noise. I'll add a 1/2 turn to each of the clamp nuts each day until sounds right.

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Old 09-24-2007, 07:09 PM   #7
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Default Re: repair exhaust flange between cc & muffler

Thats 1 way to do it. remember , those clamps will snap. They don't hold a lot of torque and will distort the shape of the pipe when clamped too tightly.

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