Exhaust removal

[Conor]

1.9 TDI ATD Engine Feb 2002 Bora.

Ok so I must have hit something when driving and it put a small hole in the exhaust. Within a few days the exhaust split in two so now i've got the bery loud hummmmmmmmmm!!

I took it to an exhaust garage where a mate works and he said that they'll only replace it. He didn't give me a price but said it'd be very expensive to replace the whole exhaust into the engine but said that where the split is, the lack of corrosian and rust, it's ideal to weld.

Took it to another mate who is a welder and he raised the car up. He's going to do it on this wednesday night 30/06/10. We've to remove the exhaust, weld it on the ground, and replace it.

Any tips on removal? We're going to weld while its on the car to get the poistion right then weld when we remove it we'll weld it completely around. The exhaust is in perfect condition expect for above. Has anyone removed and refitted the exhaust who can give some tips??

Regards,

Conor

[vwcabriolet1971]

If the hole /split is on a straight section of the exhaust then you could use a VW clamp piece to cover the hole and join the two pieces together without welding. . The clamp is specifically made to join two pieces of exhaust together as when replacing the rear tail pipe silencer .

[Conor]

No it's split in 2 now. I'm not sure of the names but it split at a junction to the catalytic converter. It's about under the handbrake position in the car. It definately needs to be welded together. Cheers anyway!

[vwcabriolet1971]

No it's split in 2 now. I'm not sure of the names but it split at a junction to the catalytic converter. It's about under the handbrake position in the car. It definately needs to be welded together. Cheers anyway!

The VW clamp I mentioned is intended to provide a leak free joint between two sections of exhaust pipe. The clamp is required for after market VW rear exhaust silencers . The original one piece VW exhaust is fitted before the rear suspension is fitted . VW provide small indentation marks to mark where the original VW exhaust should be cut when fitting a VW rear silencer.

[Conor]

I know the clamp but that can only be used when a section of piping splits/cracks and you clamp around it. Mine has broken at a joint where the sizes change thus the clamp cannot work. It's at the joint where it meets the catalytic converter and the size of piping spreads out. If it was closer to the back of the car then the clamp would be ideal but alas it ain't! Damn the thing anyway!!

Anyone else ever remove the exhaust?? Anything to watch out for??