[T3] I've got another question , same one I asked a while back.

[Jim Adney]

On 20 Jul 2018 at 21:39, willjahn wrote:

> Jim the area on the exhaust I need to fix IS the same area you spoke
> of. In order for me to be able to fit the sheet aluminum onto the HE
> pipe. to build up itTMs OD I  have to remove the EMPI header , there is
> no way of fitting the aluminum in this gap without removing the header
> and the muffler 

I understand that this will be  difficult. I use thin alum flashing from Home 
Depot or similar, which you can buy in rolls for a few dollars. Cut strips 
~1/2-3/4" wide and long enough to wrap around the HE pipe once.

Remove the muffler clamp and slide the backing ring and sealing ring 
forward just enough to be able to wrap the alum around the pipe. You may 
need to "stretch" those rings by prying under them with a tiny screwdriver to 
get them to slide forward all the way against the HE airbox.

Do a test fitting first, then wet everything with water, pack the muffler cement 
in there and slide the alum rearward under the header pipe. You may be 
able to get 2 layers of alum in there, in which case you might be able to use 
a double length piece. You can also use some ordinary kitchen alum foil 
strips to fill up the last bit of space if there's not enough room for another 
layer of flashing.

Then apply more muffler cement (muffler putty) onto everything and then 
slide the sealing ring and backing ring over everything. Install the clamp and 
tighten while the cement is wet. Then let it dry. Follow the instructions on the 
tube of cement.

Yes, it's a fiddly job, not one of my favorites, but it can usually be done.

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Jim Adney, jadney at vwtype3.org
Madison, Wisconsin, USA
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