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Author Topic: Replacing exhaust tomorrow - Tips?  (Read 1512 times)

Offline KingyMAK

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  • Model: Sharan Mk2
  • Spec: '04 PD130 ASZ
  • First Name: Mark
  • Region: North East
  • Country: United Kingdom
Replacing exhaust tomorrow - Tips?
« on: May 05, 2017, 09:58:32 PM »
Replacing from the cat back tomorrow with full system.

Any advice, as it looks like it goes through a gap in the subframe remembering off hand?
Obviously it's in centre and rear sections, so it's going to be easy enough.

Tips before I start?

Offline johnnyroper

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  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
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Re: Replacing exhaust tomorrow - Tips?
« Reply #1 on: May 05, 2017, 11:45:56 PM »
Spray any bolts/nuts with wd40 and let soak before trying to undo,can't remember how centre section joins cat off top of head.


Offline KingyMAK

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  • Posts: 180
  • Thanked: 5
  • Model: Sharan Mk2
  • Spec: '04 PD130 ASZ
  • First Name: Mark
  • Region: North East
  • Country: United Kingdom
Re: Replacing exhaust tomorrow - Tips?
« Reply #2 on: May 06, 2017, 12:21:22 AM »
It looks like it's all flared & slotted slip-together pipe.
Same goes for top.

I hope...

Offline insanitybeard

  • Greetings from Mr Chick!
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  • Model: Galaxy Mk2
  • Spec: '54 130ps TDI Ghia
  • First Name: Paul
  • Region: South West
  • Country: United Kingdom
Re: Replacing exhaust tomorrow - Tips?
« Reply #3 on: May 06, 2017, 08:46:55 AM »
I did start doing a writeup on it LOL but not yet finished ::) @KingyMAK, I've temporarily changed your membership status to allow you to view it here. Yes it's just swaged pipe joints and clamp bands, and yes, feeding the centre section between the chassis and rear axle/ subframe is the most tricky part due to the limited clearance but it is possible, it just needs to be orientated correctly, which can be easier said than done if you're working on the floor instead of a ramp. Also, the position in which the centre and rear sections are clamped relative to each other- not fore and aft but if you 'rotate' the rear box relative to the centre section it makes a big difference to how much clearance the pipe has above the subframe, I didn't set mine up right initially and the pipe was hitting it when I shook it- I was checking to make sure it wouldn't foul when going over bumps- I even thought the replacement system hadn't been manufactured correctly for a while as I couldn't seem to get it right!
Always learning..... Often by mistakes!

Offline KingyMAK

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  • Posts: 180
  • Thanked: 5
  • Model: Sharan Mk2
  • Spec: '04 PD130 ASZ
  • First Name: Mark
  • Region: North East
  • Country: United Kingdom
Re: Replacing exhaust tomorrow - Tips?
« Reply #4 on: May 06, 2017, 08:56:45 AM »
I am doing it on the floor, back end jacked up, sliding around on a shiny piece of furniture board!
I do have a set of drive up ramps, but I don't know I'd trust them to hold the weight of the old thing at a little under 2-ton...

the weather doesn't look amazing but I'll see how I go.

Also, the cat to centre looks well 'hot-and-wet-rusted-together' so I'm attempting that part before anything else!

@insanitybeard Tried to read the article and it says I'm still not authorised?

Offline insanitybeard

  • Greetings from Mr Chick!
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  • Posts: 2388
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  • Model: Galaxy Mk2
  • Spec: '54 130ps TDI Ghia
  • First Name: Paul
  • Region: South West
  • Country: United Kingdom
Re: Replacing exhaust tomorrow - Tips?
« Reply #5 on: May 06, 2017, 09:14:06 AM »
Hm, I did try changing your membergroup to RL Contributor but although it was saying that you were on the list it hadn't seemed to take effect....... perhaps you need to request it, if you go into your profile there should be an option in one of the menus for 'request group membership' or something like that, if you can find it and request it I can approve it and then just change it back when you've looked at it?
Always learning..... Often by mistakes!

Offline insanitybeard

  • Greetings from Mr Chick!
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  • Posts: 2388
  • Thanked: 70
  • Model: Galaxy Mk2
  • Spec: '54 130ps TDI Ghia
  • First Name: Paul
  • Region: South West
  • Country: United Kingdom
Re: Replacing exhaust tomorrow - Tips?
« Reply #6 on: May 06, 2017, 09:26:30 AM »
Think I've done it- your name's gone green! Try now.
Always learning..... Often by mistakes!

Offline KingyMAK

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  • Posts: 180
  • Thanked: 5
  • Model: Sharan Mk2
  • Spec: '04 PD130 ASZ
  • First Name: Mark
  • Region: North East
  • Country: United Kingdom
Re: Replacing exhaust tomorrow - Tips?
« Reply #7 on: May 06, 2017, 10:35:22 AM »
Just had a read through & it's about time I got a skip on and started it.
Sky has cleared up so I should be all good!


Let's get the cat->centre off first.

Offline insanitybeard

  • Greetings from Mr Chick!
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  • Posts: 2388
  • Thanked: 70
  • Model: Galaxy Mk2
  • Spec: '54 130ps TDI Ghia
  • First Name: Paul
  • Region: South West
  • Country: United Kingdom
Re: Replacing exhaust tomorrow - Tips?
« Reply #8 on: May 06, 2017, 11:18:15 AM »
To make it easier to remove my old centre section from the cat and avoid damage to the cat pipe itself, I very carefully cut across (at 90o) to the slit manufactured into the pipe, this allowed me to 'open up' the overlaying pipe from the centre section with some careful work using a chisel/ lever, this released the centre section pipework from the cat pipe allowing removal with minimal damage to the cat pipe:

5519-0
Always learning..... Often by mistakes!

Offline KingyMAK

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  • Posts: 180
  • Thanked: 5
  • Model: Sharan Mk2
  • Spec: '04 PD130 ASZ
  • First Name: Mark
  • Region: North East
  • Country: United Kingdom
Re: Replacing exhaust tomorrow - Tips?
« Reply #9 on: May 06, 2017, 11:30:46 AM »
Well;

Knackered back box is off...

Centre section...

Some absolute moron before me has welded the centre to the cat, but then they put the clamp over the top of the thing!
Why would you even bother!  :(

I'm guessing cutting is the only option now...?

Offline insanitybeard

  • Greetings from Mr Chick!
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  • Posts: 2388
  • Thanked: 70
  • Model: Galaxy Mk2
  • Spec: '54 130ps TDI Ghia
  • First Name: Paul
  • Region: South West
  • Country: United Kingdom
Re: Replacing exhaust tomorrow - Tips?
« Reply #10 on: May 06, 2017, 11:39:15 AM »
I'm guessing you've not got the luxury of time? If you did then there was a company on [eBay] who would basically make up stainless adapter sleeves to nearly any size you wanted, I ended up having to order one when I cut an exhaust pipe too short when fitting a new back box. If it's any help, I can try to find who it was? You could then cut the cat pipe 'upstream' of the weld and use an adapter to 'fill in' the missing bit?
Always learning..... Often by mistakes!

Offline insanitybeard

  • Greetings from Mr Chick!
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  • Posts: 2388
  • Thanked: 70
  • Model: Galaxy Mk2
  • Spec: '54 130ps TDI Ghia
  • First Name: Paul
  • Region: South West
  • Country: United Kingdom
Re: Replacing exhaust tomorrow - Tips?
« Reply #11 on: May 06, 2017, 11:53:48 AM »
Like so.........
Always learning..... Often by mistakes!

Offline KingyMAK

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  • Posts: 180
  • Thanked: 5
  • Model: Sharan Mk2
  • Spec: '04 PD130 ASZ
  • First Name: Mark
  • Region: North East
  • Country: United Kingdom
Re: Replacing exhaust tomorrow - Tips?
« Reply #12 on: May 06, 2017, 12:04:43 PM »
I do have one of these that looks the size to fit over the centre and cat section joint? Just means I could put the flared section into each other... which isn't the best idea.

Offline KingyMAK

  • *
  • Posts: 180
  • Thanked: 5
  • Model: Sharan Mk2
  • Spec: '04 PD130 ASZ
  • First Name: Mark
  • Region: North East
  • Country: United Kingdom
Re: Replacing exhaust tomorrow - Tips?
« Reply #13 on: May 07, 2017, 12:04:28 PM »
Well; it got done yesturday.

I started around about 3-4pm properly, as went out for a bit family time.
(Without the backbox, but it wasn't connected before anyways!)

I got down to business, when I saw that the cat had been welded to the centre section, but it had also had a piece of pipe put over the top and welded on, then a clamp applied, too.
I broke out the Dremel, a hacksaw and my machine polisher with a 40 grit and got to work.

It was fairly easy considering it was done about 6-10 inches off the floor!
My daughter loved the sparks coming off the grinding of the welds.
So did all the other kids on the street!  :D

Anyways; the hardest part was probably getting the old hanger rubbers off the hangers!
Putting them in was a little awkward, so I did use a bit of lube to squeeze them into the hangers.


Anyways!

Heres some photos!

Offline mike wilson

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Re: Replacing exhaust tomorrow - Tips?
« Reply #14 on: May 08, 2017, 10:00:55 AM »
For future reference, Spanner Monkeys, on the Felling trading estate NE10 0QH , will make and fit you a custom stainless system for about the price of the OEM parts.

The website's not fully functional yet but they seem to be a good team.

http://spannermonkeys.co.uk/

Offline insanitybeard

  • Greetings from Mr Chick!
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  • Posts: 2388
  • Thanked: 70
  • Model: Galaxy Mk2
  • Spec: '54 130ps TDI Ghia
  • First Name: Paul
  • Region: South West
  • Country: United Kingdom
Re: Replacing exhaust tomorrow - Tips?
« Reply #15 on: May 08, 2017, 10:43:58 AM »
Well; it got done yesturday.

I started around about 3-4pm properly, as went out for a bit family time.
(Without the backbox, but it wasn't connected before anyways!)

I got down to business, when I saw that the cat had been welded to the centre section, but it had also had a piece of pipe put over the top and welded on, then a clamp applied, too.
I broke out the Dremel, a hacksaw and my machine polisher with a 40 grit and got to work.

Looks like your backbox went in exactly the same place as mine was going- the pipe weld on the forward (inlet) end of the box. The rear pipe weld on the centre box was going the same way on mine as well. So you managed to grind the weld off of the centre section to cat pipe joint leaving the cat pipe in a good enough condition to join the centre section to it normally without any adapters or additional sleeves? That's a result!  [GJ]
Always learning..... Often by mistakes!

Offline KingyMAK

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  • Posts: 180
  • Thanked: 5
  • Model: Sharan Mk2
  • Spec: '04 PD130 ASZ
  • First Name: Mark
  • Region: North East
  • Country: United Kingdom
Re: Replacing exhaust tomorrow - Tips?
« Reply #16 on: May 08, 2017, 11:14:24 AM »
Looks like your backbox went in exactly the same place as mine was going- the pipe weld on the forward (inlet) end of the box. The rear pipe weld on the centre box was going the same way on mine as well. So you managed to grind the weld off of the centre section to cat pipe joint leaving the cat pipe in a good enough condition to join the centre section to it normally without any adapters or additional sleeves? That's a result!  [GJ]

It certainly wasn't easy being extra careful, but it got done! That's the main thing;

I also learnt my ramps will take the back end weight of the old beast, so it'll make things easier for other jobs I have planned!

 

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