So this started with a leaky catalytic converter which I'm hoping to repair (minor leak near flange).



My exhaust goes from the CAT to the muffler with no resonator.







Removed that CAT...





Just needs some cleaning up and some repair sealant near the flange area.

Here's the flange for the center pipe.



And the exhaust looks pretty good.



I think it might be a better quality one. Not sure.



So I'm thinking I only need to replace the center pipe. What's the best way to build/do this? I was thinking about installing the CAT and muffler in their correct locations and hanging heights. Then finding or reusing the flange from the center pipe and trying to build a pipe out of various pieces I can find at the auto store. Then using exhaust sealant on the joints and clamps hangers to bring it all together. Or does someone sell a curved center pipe to take you from the CAT to the exhaust with no resonator? I'm sure it would be tough otherwise to get a combination of piping that sits close to the car and bends correctly.

Take it to a muffler shop.
I recently replaced my center muffler. They cut out and welded in the replacement. 30 minutes and $50.

Save yourself the aggravation=-O

wizard124 wrote:Take it to a muffler shop.
I recently replaced my center muffler. They cut out and welded in the replacement. 30 minutes and $50.

Save yourself the aggravation=-O

Far too easy. I've cleaned up the muffler (it actually looks in really great shape) and fixed (hopefully) the CAT with exhaust crack sealant inside and out (not sure the inside will last but we'll see). Probably put the CAT and muffler back in their exact correct position and bring it to a muffler shop. $50? Probably not in Canada. Seems prices here (especially for car work) are crazy expensive.

I think I'll paint the muffler. Looks like it was painted back before so I'll go with that. Is it worth painting the exhaust pipe itself to prevent rusting? Got everything apart. Might as well do it right.

Or maybe I could just buy this?

http://www.autoricambi.us/product/EX7-4 ... -Injected/

Assuming the CAT and muffler are standard would that part just slip in between?

Do you need a catalytic converter? I'd buy the center piece you linked to and put in a test pipe in place of the cat. And, yeah, paint it black.

Nanonevol wrote:Do you need a catalytic converter? I'd buy the center piece you linked to and put in a test pipe in place of the cat. And, yeah, paint it black.

Don't need the CAT but I'll try my repair 1st and if it still leaks exhaust then I'll replace with the test pipe from AR.

Sanded and painted with 3 coats of VHT black exhaust paint. VHT recommends 2 light coats followed by 1 heavy coat with 10 minutes drying time in between.

From this...


To this...




Still have to do burn in cycle when I get the full exhaust connected up. I'll probably get an exhaust shop to connect from the CAT to the muffler pipe. Want to ensure it's tight to the body (without touching!) and doesn't burn my emergency brake cable!

Just reinstalled muffler into the rubber support hangers. The pipe out of the muffler goes over but comes pretty close to the wide sway bar that connects between the wheels. If I have the rear tail pipes (the chrome part) horizontal the pipe is about 3/4" away. Is that ok as long as it's supported correctly? Just wanted to ensure there isn't much movement in the sway bar when the car goes over bumps.

you will know if you have a problem with the first big bump you hit and you hear the exhaust pipe clank

azruss wrote:you will know if you have a problem with the first big bump you hit and you hear the exhaust pipe clank

True enough. I'll listen for that.

Ordered this part from AR this morning.

http://www.autoricambi.us/product/EX7-4 ... -Injected/

It will just fit. I had so much run around with people in Ottawa re. bending a pipe (crush bend vs bendral) and I want to do this right. I can't believe how reasonable we can get parts for a 30+ year old Italian car... Thanks AR!

Got the middle section of exhaust for my '81 and it fits the body contours great. I bolted it up to the CAT no problem. At the ANSA muffer end it wouldn't go in. It butted up against the end of the muffler. Here's the muffler where the middle section should attach.



Looks like the PO put in an diameter adjustment piece inside the muffler to fit the middle section piece that was put in place of the original. It looks like it slides into the muffler and is about 2 1/2" long. Any chance I could get this piece out? I don't see any weld points but maybe the PO used muffler adhesive or something. I'm sure that if I got that piece out the middle section of the muffler would fit in perfectly. Argh! Or should I just cut the muffler and patch in a piece to get the right diameter?

It slid into the PO's muffler, maybe it could slide into yours.
http://www.harborfreight.com/medium-tai ... -9208.html
Otherwise...hacksaw?

Nanonevol wrote:It slid into the PO's muffler, maybe it could slide into yours.
http://www.harborfreight.com/medium-tai ... -9208.html
Otherwise...hacksaw?

Don't have that tool but may get one if required.

Trying to remove the inner pipe using a BFH and a flat screwdriver. I'm able to work it inward but it's very tight for sure. I guess eventually it will break free (I hope). Otherwise I'll probably cut out the 2 1/2" of muffer and patch in a piece. Also going to try some heat on the outer pipe but I only have propane so could take a while.

I have a dremel but I don't have a bit that would cut inside a pipe.