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

[William Jahn]

it's 3661

On Sat, Jul 21, 2018 at 2:46 PM, William Jahn <willjahn975 at gmail.com> wrote:

> 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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>
>
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