Tiny hole in exhaust - how to seal up?

[steve_earwig]

Check prices (then collapse...)

If the system is the same on a crocus would it be worth looking out for a full system off a wrecked one? I suspect they're much more likely to be crashed...

[Doggy]

Pimp the Volvo to the max, use 1 day per month followed by 30 days penance in the Citroen.

[Bailes1992]

I looked into fitting a Volvo V60 Exhaust onto my Mondeo and they wanted £600 for the full system from the CAT backwards.

I got a custom exhaust fabricated for £250 inc VAT in T304 stainless with a lifetime guarantee. Maybe worth considering? The T5 engine does sound lovely on full chat but Volvo done a good job at making it damn near silent in my Fathers V50. I imagine your S40 is the same? Bit of a grumble upto 4k and then... silence!
Or you could have them make you an exhaust even quieter if that's your thing?

[Welly]

I can't believe this has been an issue for over a year however my excellent* idea of using high-temp mastic bound with wire has only proved a temporary fix, I guess I've renewed it maybe 4 times and lasting a few months until I forget...investigate....and find it blowing again.

Next phase is to try Gun Gum history suggests this stuff will not work but I'm more hopeful with the 'leak' being a small crack rather than a gaping hole. Reading the tin of gobbo that turned up it suggests warming the eggsauce first and then applying a bit of water whilst smoothing the repair paste into and over the hole. I've also got some stainless steel lacing wire from work which I'll use to reinforce the patch.

Repair capers to commence this weekend. Those who might say "replace the exhaust" it's not available for my Volvo unless you go main dealer or specialist aftermarket, minimum £500.00. It's one of those annoying issues, the leak can't be heard normally until you get your head down near the exhaust where its then a small but silly 'fuffing' sound reminiscent of a 1984 mini metro

[trufflehunt]

I've used Gun Gum at various times over lots of years. If you get a fortnight out of a Gun Gum repair, that'll
be doing quite well.

The best repair I've ever done with an exhaust was on my 406, as mentioned above. Some adhesive aluminium
tape, ( Poundshop ) wrapped round the exhaust. Followed by some high-temperature tape that, with exhaust heat, bonds to itself.
Quik Tape is the brand that I used, but others available.

[Welly]

Problem I have truffy is that this leak is right on the entry to the back box AND on a bend so I have about 4mm one side and loads of room the other, I can't centralise a patch over it.

I have faith in the Gun-gobbo, it will work.


(Watch this fail).

[Doggy]

Probably not relelvant - I attempted to fix a few perforations in a Triumph Dolomite fuel tank, (when Bright Eyes was No. 1).
Failed many times with the recommended 'Petro-Patch' bodge, but some P40 fixed it first try.

[Bailes1992]

Welly, have you been to an exhaust fabricators and seen how much it would cost to get one made up in stainless steel? I paid £250 for mine at a reputable exhaust fabricator called pro-speed in Cardiff. They build it to your specification and make it sound how you want it to!

[Welly]

I haven't looked into that yet no, cheers for the idea I was kinda thinking it'd be best to buy a sport-type system from Ferrita or similar.

Anyhoo, I cleaned up the area and it's a definite 'split' about 10mm long near a chunky weld into the back box. Heated up the area with a small flame, 'wet' it first then squished some Gun Gum into the hole then applied more over it in layers. Introduced some stainless steel lacing wire and further layers and let it dry for 24 hrs.

This morning there was no leakage at all, watch this space....

[mjb]

What about just getting a garage to weld it up?