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

[William Jahn]

Last time I looked at this leaky connection I could see the metal ring was
already as far forward as it can possibly go with the clamp off and the
mesh so called sealing /packing is as far forward as it can go . I can only
pull the header back enough to see about 1/4" of the HE pipe , if let go it
goes right back into place. I would need to find a way to pull it back
further and hold it there to even attempt to fit the aluminum sheet in
there . These headers are a bit different than a stock muffler . The stock
unit is a straight tube with the flare , the header where it fits over the
HE pipe has a ID the same at the stock unit about 1 1/2" long then goes
down to the same ID as the header pipes plus the flare where the clamp fits
over is a bit larger in diameter and not tapered it's more like a thick lip
. I did file it a bit and it's tapered inside to fit the mesh seal . It's
just a really poor design . I should have filed it down long ago because
that lip allows the clamp the stop before the metal ring is covered. Now
days much better hears are offered than what was out there in 96 . EMPI
still makes this POS .

 All I can do is file that flange/lip OD down more with it still in the car
and taper it a bit more then see if I can get the aluminum in there. I also
think the wall diameter is thicker than the stock unit it's about 1/16"
thick . The HE pipe is not pitted it had rust scale on it , part of this
was what was left of the stock muffler pipe and somehow the HE pipe eroded
with it. If I had left that layer of rust on it then it might have sealed
yet I thought it was just from the muffler pipe which was very thin.

This is the one I have
http://vwcatalog.empius.com/vwcatalog/2018/pages/204.jpg

On Sat, Jul 21, 2018 at 7:25 AM, Jim Adney <jadney at vwtype3.org> wrote:

> 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.
>
> --
> *******************************
> Jim Adney, jadney at vwtype3.org
> Madison, Wisconsin, USA
> *******************************
>
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