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How to fix exhaust broken at the flange? #5264643 11/11/19 10:53 PM
Joined: Mar 2008
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slacktide_bitog Offline OP
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Posts: 9,108
1996 I30 (Maxima)

The weld right after the flange on the resonator broke off and rusted. The flange from the cat and the flange from the resonator are rusted together. mad mad mad

I can't use the typical soup can method because it won't fit around the flanges. I tried Tiger Tape (an exhaust wrap), but it didn't work.

Is there anything string or wire-like I could wrap around it? Twine, some kind of wire, something like that I could use?

I don't want to spend too much money because I am dumping the car soon. A new Y-pipe and converter will cost too much, and a universal cat won't work because on this car, the oxygen sensor is mounted right after the cat, and it is an unusual size (not the typical 22mm nut and whatever large thread that is), but a smaller 14mm nut, and the sensor is only 3 wires rather than the typical four.

I grabbed this from a YT video to show you what my exhaust looks like. Right now, the green dotted line is where mine broke off. Both the flanges on one side, and the resonator and pipe are on the other side.

[Linked Image]


Re: How to fix exhaust broken at the flange? [Re: slacktide_bitog] #5264661 11/11/19 11:37 PM
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rooflessVW Offline
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Take it to an exhaust shop and have them weld on a new flange. Have them remove the flange entirely and weld it solid.

Could probably have it done for 50 bucks or so.

Re: How to fix exhaust broken at the flange? [Re: rooflessVW] #5264676 11/12/19 12:14 AM
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c502cid Offline
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Originally Posted by rooflessVW
Take it to an exhaust shop and have them weld on a new flange. Have them remove the flange entirely and weld it solid.

Could probably have it done for 50 bucks or so.


^^^^This is the answer^^^^


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Re: How to fix exhaust broken at the flange? [Re: rooflessVW] #5264745 11/12/19 06:24 AM
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jeepman3071 Offline
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Originally Posted by rooflessVW
Take it to an exhaust shop and have them weld on a new flange. Have them remove the flange entirely and weld it solid.

Could probably have it done for 50 bucks or so.


+2


1998 Jeep Wrangler Sahara 4.0L/5MT (156k) - PHM 10w30, Wix 51085
2009 BMW 328i N51 (53k) - Castrol Edge Euro 0w40, MANN HU816X
Re: How to fix exhaust broken at the flange? [Re: slacktide_bitog] #5264884 11/12/19 09:59 AM
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Scuder Offline
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If there is enough left on the pipe, and hopefully even a little bit of the flare, you might try a split repair flange. Like it sounds, it is a two-piece flange, meant to replace a rusted or broken original. Some are a clamp style, meant to grip the pipe in the event there is no flare to hold it.
I had a flange fail at the converter, dropping the pipe on the road. It was a winter car on which I didn't want to spend a bunch replacing it cat back. Eight bucks, saved my bacon. Didn't know they existed until the knowledgeable counter man (remember them?) suggested one.
Google shows a few different types, and naturally they're more expensive now, but still a cheap alternative.
Good luck.

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