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Exhaust clamp rusted/leaking
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Posted 5/22/2013 11:36 PM
Otiswesty
Administrator




Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3005
2000
Re: Exhaust clamp rusted/leaking

fernweh - 5/22/2013 6:49 PM

Don't you remember Charlie Tuna? .....Sorry Charlie,.....

Must have been before your time

Karl



It was a regular commercial during the Little Rascals episodes
#214177 - in reply to #214174
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Posted 5/23/2013 9:36 AM
94rover
Veteran




Date registered: Oct 2010
Location: 39.2036° N, 76.8569° W
Vehicle(s): 02 G500
Posts: 240
100
Re: Exhaust clamp rusted/leaking

WOW!, thanks for the resonator pipe image Karl.

I remember the commercial http://www.youtube.com/watch?v=Rk0xqDcHu04

Edited by 94rover 5/23/2013 9:38 AM
#214184 - in reply to #213935
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Posted 5/23/2013 3:51 PM
hipine



Date registered: Jul 2006
Location: US, CO, Bailey
Vehicle(s): 460 1980 280GE w. 617A
5000
RE: Exhaust clamp rusted/leaking

94rover - 5/21/2013 8:55 AM

Last Saturday while planning out my day I recalled the shop that installed the y-pipe on my Classic way back in 99 and decided to visit and get a quote on repairing my exhaust. Glad I did. The shop owners remembered me and were more than thrilled to "make the simple fix"

Only took 20 minutes and didn't cost me more than an hour conversation.


Good move. Clearly lots more wrong there than just a bad flange ring. I guess they welded in new bell and flare ends fitted with new flanges and bolts. Good fix. Thanks for sharing.

-Dave G.
#214186 - in reply to #214130
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Posted 5/23/2013 8:47 PM
94rover
Veteran




Date registered: Oct 2010
Location: 39.2036° N, 76.8569° W
Vehicle(s): 02 G500
Posts: 240
100
RE: Exhaust clamp rusted/leaking

Correct, a small hole underneath the rusted flange. Shop owner featured in the pic knew exactly what to do. I've known him for years and trust and value his opinion/judgement on automobile service (aside from the fact that he owns a nice brand new GL55 and a HOT 09 Lamborghini Murcielago and is a couple of years younger than me). He decided the simple approach would be to just cut and weld in a steel extension until I purchase Karls resonator. So far all is well because I can't find any faults sound wise. I was so busy talking "exotic cars" I failed to snap a pic of the finished work before they lowered my G and sent me on my way.



(IMG_20130523_170403.jpg)



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Attachments IMG_20130523_170403.jpg (78KB - 0 downloads)
#214189 - in reply to #213935
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Posted 5/23/2013 11:27 PM
hipine



Date registered: Jul 2006
Location: US, CO, Bailey
Vehicle(s): 460 1980 280GE w. 617A
5000
RE: Exhaust clamp rusted/leaking

94rover - 5/23/2013 6:47 PM

....he owns a nice brand new GL55 and a HOT 09 Lamborghini Murcielago and is a couple of years younger than me....


Well he's either doing something right as a muffler welder, or he's got a business importing mufflers from South America with a very special sort of sound deadening packing inside....

Looks like you're good to go for a good long time.

-Dave G.
#214191 - in reply to #214189
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Posted 3/27/2016 11:28 PM
Otiswesty
Administrator




Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3005
2000
RE: Exhaust clamp rusted/leaking

Well, I have been driving around with rusted and broken exhaust clamps for a few years. A couple of years ago I ordered a couple of different split flange types and settled on one from a Canadian company, Exhaust Direct Ltd. I finally ordered up a full set over the winter, 2 x 2 1/4 inch, 2 x 2inch, and 4 x 2 1/2 inch. So last week I finally developed a big exhaust leak that I knew was coming. This was at the center muffler above the frame rails where the bolts had pretty much disappeared and one of the stock flanges was really thin and also broken. The flanges in front of the cats were thread thin and rattled around loose on the pipe. Yeah, you could say I've been putting this one off.



(Thin.jpg)



(compression.jpg)



(Cat.jpg)



(Rear.jpg)



(Copper.jpg)



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Attachments Thin.jpg (312KB - 0 downloads)
Attachments compression.jpg (178KB - 0 downloads)
Attachments Cat.jpg (241KB - 0 downloads)
Attachments Rear.jpg (338KB - 1 downloads)
Attachments Copper.jpg (163KB - 0 downloads)
#231969 - in reply to #213935
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Posted 3/27/2016 11:41 PM
Otiswesty
Administrator




Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3005
2000
Re: Exhaust clamp rusted/leaking

The front exhaust joint is a slip joint, so I left the original front flange in place to press into the seam between the two pipes. The down pipe is 2" OD and the female side is a little under 2 1/4" OD.

The joints on either side of the center muffler are butt joints (he he) with a compression ring between the flared ends. I gooped this up with copper exhaust paste and put a 2 1/2" clamp on either side. Super tight with no leaks, but it took about 2 hours with all of the cutting and grinding. I found a pile of old VW case bolts that are 10.9 and paired them up with some thick seat belt washers.

Here is where I got the split flanges. They are about 1/3 the price of the Ebay items from the same manufacturer. Eight clamps and shipping was under C$100.

http://exhaustdirect.com/Split-Flange

The thin metal "wire" in the last pic is actually a small gauge steel fuel line for the Webasto heater. I busted it while getting to that right sided rear clamp. Now I know why I have not been able to get that thing working properly. Rust on the inside made it solid all the way through. Now I just need to sort a good 5 meter length of that.
#231970 - in reply to #213935
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Posted 3/31/2016 1:42 AM
PUCH G.
Member


Date registered: Mar 2015
Location: Portland, OR. USA
Vehicle(s): 1998 Puch G320 LWB
Posts: 7

Re: Exhaust clamp rusted/leaking

Awesome fix!
#232008 - in reply to #214135
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Posted 4/1/2016 1:39 PM
Braingears
Expert




Date registered: Apr 2006
Location: St Petersburg, FL
Vehicle(s): G320 & ML320
Posts: 1450
1000
RE: Exhaust clamp rusted/leaking

Can the Catalytic Converter be removed? If I am correct, I have an O² sensor in front of and behind the Catalytic Converter for my M104 inline 6 cyl. engine.
#232023 - in reply to #213935
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Posted 4/2/2016 11:50 PM
Otiswesty
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Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3005
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Re: Exhaust clamp rusted/leaking

I have dual catalytic convertors side by side on the right side. There is an O2 sensor before and after each, 4 in total. I suppose they could be removed, but may make it difficult to pass emissions.

Is your 1998 G320 the M104?
#232024 - in reply to #231970
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Posted 4/3/2016 4:20 AM
jmr89



Date registered: Nov 2012
Location: France
Vehicle(s): Class G W463 320Cab V6 >>Ancien 230 GE Cab 1990
100
Re: Exhaust clamp rusted/leaking

otiswesty hello

Could you give us the reference of necklaces that you used
because we do not find these collars in France



Thank you very much
#232025 - in reply to #213935
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Posted 4/3/2016 6:50 AM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
5000
Re: Exhaust clamp rusted/leaking

jmr89 - 4/3/2016 4:20 AM

otiswesty hello

Could you give us the reference of necklaces that you used
because we do not find these collars in France



Thank you very much


Link in this message:

http://pointedthree.com/disc/forums/showthread.php?tid=20651&mid=23...
#232026 - in reply to #232025
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Posted 4/3/2016 10:09 AM
jmr89



Date registered: Nov 2012
Location: France
Vehicle(s): Class G W463 320Cab V6 >>Ancien 230 GE Cab 1990
100
Re: Exhaust clamp rusted/leaking

I see no reference to the diameter
#232028 - in reply to #213935
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Posted 4/3/2016 11:36 AM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
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Re: Exhaust clamp rusted/leaking

jmr89 - 4/3/2016 10:09 AM

I see no reference to the diameter


Read the message I linked a little closer. The information is there.
#232029 - in reply to #232028
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Posted 4/3/2016 1:22 PM
jmr89



Date registered: Nov 2012
Location: France
Vehicle(s): Class G W463 320Cab V6 >>Ancien 230 GE Cab 1990
100
Re: Exhaust clamp rusted/leaking

it is not hollowing with the Google translation
#232032 - in reply to #213935
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Posted 4/4/2016 12:27 AM
Otiswesty
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Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
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Re: Exhaust clamp rusted/leaking

I used 2 units of the 2 inch FFS200 on the down pipe from the motor
I used 2 units of the 2 1/4 inch FFS214 in front of the catalytic convertor
I used 4 units of the 2 1/2 inch FFS212 for either side of the center muffler

I ordered all the flanges from
http://exhaustdirect.com/Split-Flange/
#232033 - in reply to #232024
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Posted 4/4/2016 12:35 AM
Otiswesty
Administrator




Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3005
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Re: Exhaust clamp rusted/leaking

This Ebay seller ship internatinally
http://www.ebay.com/itm/Fits-2-Pipe-Exhaust-Repair-Oval-Split-Steel...
http://www.ebay.com/itm/2-1-4-2-25-Exhaust-Repair-oval-SPLIT-FLANGE...
http://www.ebay.com/itm/2-1-2-Exhaust-Repair-oval-SPLIT-FLANGE-flat...
#232034 - in reply to #213935
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Posted 4/4/2016 4:00 AM
jmr89



Date registered: Nov 2012
Location: France
Vehicle(s): Class G W463 320Cab V6 >>Ancien 230 GE Cab 1990
100
Re: Exhaust clamp rusted/leaking

OK THANK YOU

Edited by jmr89 4/4/2016 4:01 AM
#232035 - in reply to #213935
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Posted 4/4/2016 7:41 AM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
5000
Re: Exhaust clamp rusted/leaking

otiswesty - 4/4/2016 12:27 AM

I used 2 units of the 2 inch FFS200 on the down pipe from the motor
I used 2 units of the 2 1/4 inch FFS214 in front of the catalytic convertor
I used 4 units of the 2 1/2 inch FFS212 for either side of the center muffler

I ordered all the flanges from
http://exhaustdirect.com/Split-Flange/


Vielen Dank!!

PS - Don't you have two down pipes and two cats? Was one of them OK and of no need to be reclamped?
#232036 - in reply to #232033
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Posted 4/4/2016 11:59 AM
Otiswesty
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Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3005
2000
Re: Exhaust clamp rusted/leaking

Yes, two down pipes and 2 cats. A 2" clamp on each down pipe, and a 2 1/4 inch clamp on the cat side of each joint.

Pic from above showing this



(Cat.jpg)



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Attachments Cat.jpg (241KB - 0 downloads)
#232038 - in reply to #232035
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