I have 3 potential exhaust systems that can go in my 2.2 engine swap (including the original). But all are afflicted with the wasted stud issue. I didn't want to/couldn't heat up with a torch to whack the studs out and the flange was too wasted on the original anyway so...
1 of the systems I cut through on the manifold side to remove. 1 of the systems I cut through on the system side. So in other words I have 1 potentially useable system and 1 potentially useable manifold both with stubs from the other side to remove. Plus 2 scrap/cut pieces of exhaust
I then have a 3rd one in reserve which came from spurs fan. This was cut in the middle of the system and removed as 1. back box and 2. cat with manifolds still joined. I could just use that but I really don't want to get into taking the manifold off at the head - way too much agro.
The manifold end (ie attached to the replacement engine - which is now back in the car) has been cleaned up by very carefully carving an angle grinder through the system stump. And then cutting a relief slot in the side of the manifold flange to provide some give to whack the stud out. It worked! I do have 4 small slots but I'll infill these with JB Weld Extreme Temp although I don't think it's vital as there's enough metal left to be secure (I hope).
Are you following?! So this is what it looks like at the manifold end.
If you're not following the question boils down to this. Are the flanges welded onto the pipes or just stuck fast with rust? In other words I'd like to know if I can use one of these repair kits.
I know I have the option of having easily available weld-on flanges put on but that's more money, more delays and to be honest no guarantees the whole thing is going to line up unless I take it to an exhaust centre who will no doubt just want to put an entire new system on...
I could also cut both flanges off and put a flexible repair section on but these are typically 6" long and I don't think there's enough straight run either side to do this.
Any thoughts appreciated. I think this issue is going to hold up getting the car back on the road
1 of the systems I cut through on the manifold side to remove. 1 of the systems I cut through on the system side. So in other words I have 1 potentially useable system and 1 potentially useable manifold both with stubs from the other side to remove. Plus 2 scrap/cut pieces of exhaust
I then have a 3rd one in reserve which came from spurs fan. This was cut in the middle of the system and removed as 1. back box and 2. cat with manifolds still joined. I could just use that but I really don't want to get into taking the manifold off at the head - way too much agro.
The manifold end (ie attached to the replacement engine - which is now back in the car) has been cleaned up by very carefully carving an angle grinder through the system stump. And then cutting a relief slot in the side of the manifold flange to provide some give to whack the stud out. It worked! I do have 4 small slots but I'll infill these with JB Weld Extreme Temp although I don't think it's vital as there's enough metal left to be secure (I hope).
Are you following?! So this is what it looks like at the manifold end.
If you're not following the question boils down to this. Are the flanges welded onto the pipes or just stuck fast with rust? In other words I'd like to know if I can use one of these repair kits.
I know I have the option of having easily available weld-on flanges put on but that's more money, more delays and to be honest no guarantees the whole thing is going to line up unless I take it to an exhaust centre who will no doubt just want to put an entire new system on...
I could also cut both flanges off and put a flexible repair section on but these are typically 6" long and I don't think there's enough straight run either side to do this.
Any thoughts appreciated. I think this issue is going to hold up getting the car back on the road
