REPAIRING THE EXHAUST

miggy24 · Unread post by **miggy24** » 21 Feb 2010, 18:30

Hi guys well after iv just finshed repairing my car i took the car out to see if everything was ok.But when i was sat at the traffi lights i pulled off then there was aloud noise coming from the exhaust so i go it home up on the ramp and whats happend is that where the pipe goes into the rear box had broke apart but the this happend to the last owner and he had just put loads of the exhaust paste onit so is there anyother way to repair it without having to weld it and would be fine for the mot as i have the mot in april and i dont really wanna have to buy a whole new exhaust

andmcit · Unread post by **andmcit** » 21 Feb 2010, 18:43

I'm guessing this is the newly repaired (battenberg coloured?) Xantia TD estate?

I've found out in the past that bodging with paste etc or welding even costs
more in materials and time spent than fitting a decent replacement in the
first place!

Your only real way to sort this permanently is to get a replacement
connecting section of exhaust. If it's the main feed between the front
box and the rear one or the actual rear box flange - you'll need to make
an accurate examination to make the right replacement.

The best way is to see what's on offer on ebay as sometimes there are
clearance bargains where the postage is higher than the cost of the pipe!
Alternatively a decent section off a scrapper if funds are tight?

Andrew

Featch · Unread post by **Featch** » 21 Feb 2010, 18:55

I've used tins cans, pop rivets and jubilee clips with some success in emergencies but they tend not to last long. More get you home really.

Cans can be cut with good scissors. If you split them length ways and slide one inside another you can make any diameter. If it's rotted at the box then you can make a flange out of a Fray Bentos pie tin and attach with self tappers or pop rivets. Clamp it all up with Jubilee clips and paste.

I've welded many exhausts, back in the days when I had the facilities, and to be honest it's not worth the effort... you fill one hole and another appears a couple of weeks later.

Best to mend it with a new one really

red_dwarfers · Unread post by **red_dwarfers** » 21 Feb 2010, 19:32

Another Devonian

Great stuff!

The exhaust on mine was falling apart a bit on that join aswell as on the cat, I did weld it up while GSF had the new one on order (full length from manifold to rear box including a cat for about £36!) though the metal was getting fairly thin so it could have only been a tempory measure.

Unread post by **Old-Guy** » 21 Feb 2010, 21:59

This happened to us - there's obviously a jinx on Xantia exhausts in Devon - our rear box came adrift at the top of Kingsbridge shortly after we'd started our 130 mile return journey back to Gloucestershire. Turn round, creep back to our daughter's (sounding like a tractor), borrow old clothes, grovel under back of car with big pliers, a metal coat-hanger (to bodge a bracket for the pipe) and some fire-gum.

This seems to be a common failure, the box end-plate rots through where it's welded to the pipe flange. When I fitted a new box, I sprayed two coats of wood-stove paint on both end-plates.

Replacing the box is the only sensible repair, not too expensive and easy enough to do - the box is fairly heavy - looks more the size for a small truck!

rory_perrett · Unread post by **rory_perrett** » 21 Feb 2010, 22:17

I've had 2 (Xantia) go there and 3 (2 x Xantia 1 x Xsara) at the rear of the Cat on diesels. Must say I've managed to weld them up so they've lasted a few years. Considerably cheaper than buying a new one. Paying someone else to do it would be another matter!

HDI · Unread post by **HDI** » 21 Feb 2010, 23:15

Ditto. I welded the flange back onto the rear box just after I got the car 4 years ago and it has only JUST gone again !! Haven't had a closer look yet so not sure if it will weld again.

jonathan_dyane · Unread post by **jonathan_dyane** » 22 Feb 2010, 23:43

If it's a decent quality silencer, you can usually get away with welding the flange on once (if you're a reasonable welder) and it should last a good few months.

Some years ago I returned from nightshift, and before collapsing into bed said goodbye to the parents who were off to France in their Xantia TD estate and caravan.

I'd only just fallen asleep when I was woken by the very impressive sound of the unsilenced XUD, and was dragged out of bed to weld the flange back on

Did a lovely job though, and it lasted ages. I think this was a couple of days after I investigated what mother termed a 'funny noise' and discovered a strut preparing itself to launch through the bonnet. Thankfully the local scrappy had a lovely strut top for £20, not so easy to find now...