Fitting a new exhaust back-box to an estate

[DrRog]

Hi guys,

I suspect I may have put this thread in the wrong place, like my last one, but it just adds to the fun. Just for once this is not a cry for help, but some advice would be appreciated.

Last Friday by back-box connection clamp/ring thing fell apart due to rust, the mid section twisted and clouted the road. The B-B was holed anyhow and beyond repair (I have been that desperate) so I got a new one today. £60 ish for a solid one.

The mid box was in pretty good nick so I spent plenty of time knocking the end back into a bell shape. amazingly I could rotate it at the joint with the front section by hand. No wonder there is soot marks coming out of the joint.

I managed to align it all up and get it together - what a faff those V section clamps are a pain to get in place when covered in sealant, you need three hands and a few extra supports. Maybe a G-clamp to close it up a bit to allow you to spin the nut. Obviously easier if underneath the car but I wanted to do a quick job and left the car on the ground except for a couple of bits of 2" wood and slid under.

At this point I remember 4 hours spent in Medway eye hospital and remind everyone to wear eye protection.

Next job is to re-do the forward joint. The nut is screwed down so far I think it may be the wrong clamp. I couldn't get a ring spanner on it.

Question - is this a common problem? What did you do about it? - the twisting not the B-B rusting but then again....

Cheers
Rog

[gumby6371]

I agree completely that the clamps are stupid, very easy to take a nice new exhaust apart compared to 'U' bolts but useless once the rust sets in.
I drive a D8 saloon so a different set-up but I'm surprised the mid section was able to twist.
I'd imagine there should be a bracket for a rubber just before the mid section meets the back box which would support the end and stop it twisting.
Like I said mine is a different set up but I'd be looking for evidence of a broken weld where a bracket used to be on the mid section.

I'm sure an estate owner will be along soon with more info.

[Doggy]

99% sure the only difference with an estate is the tailpipe's about an inch longer, i.e. everything apart from the back box is identical.

Replacement clamps from Pug were about a fiver, last time I got one. They do come in several sizes, think it'll be a 66 mm you need.

[DrRog]

I'd imagine there should be a bracket for a rubber just before the mid section meets the back box which would support the end and stop it twisting.
Like I said mine is a different set up but I'd be looking for evidence of a broken weld where a bracket used to be on the mid section.

Its there, but its on the opposite side to the back box. When the joint failed it pushed down the bend in the mid section, the support on the other side makes little difference.