cast iron exhaust fitting

Post by **hammy44** » 06 Jul 2007, 07:50

have just got the cast iron piece for the exhaust 2.1 dj from gsf has anyone fitted one of these and what problems might i encounter. the exhaust might be the origonal as some of the bolts are very thin (rusted away) have been spraying releasing fluid round them the last few days.any advise on this job appreciated

Post by **toomanytoys** » 06 Jul 2007, 08:26

Dont try and do it up too tight.. they break if you do...

Post by **jonno** » 06 Jul 2007, 10:22

Replaced mine last month.
The nuts and bolts had rusted that much on the back end i couldnt get a spanner or vice grips on them. Ended up cutting through the gasket and then drilling the seized bolts out.

Post by **Ian Hulley** » 06 Jul 2007, 10:58

Jack up the N/S/R and remove the wheel. Use a small angle grinder and thin slitting disc to cut away the heads on the exhaust pipes side, the 2 top ones are a barsteward to get to but .... Then using a thin chisel or screwdriver

gently try to split the gasket joint. The bolts may just be freed off by the heat .... probably not though. I had to drill our's out.

Be prepared for the job to escalate. Use a full face visor and cover your ears (I had a red-hot piece of bolt drop into my ear ... which was interesting

gave the neighbours a laugh though as they watched me pour a cold cup of coffee into my ear) Replace the M8 x 30 bolts with new (stainless if you can get them ... that way next time they'll still be there AND still be 13mm across) also use the copper 'aerotype' exhaust nuts ... again they'll actually come undone again next time.

Use exhaust paste and the gaskets .. belt and braces ! Don't plan on doing anything else that day and keep any children or easily upset adults away from the ensueing debacle !

Good luck, Ian.

Post by **hammy44** » 06 Jul 2007, 16:14

thanks for the replies. i thought it might end up a drilling job now i know what to expect.thanks again

Post by **Hacksawbob** » 07 Jul 2007, 08:52

Tungsten bolts are better than stainless, costs about £30 for all 8.

Post by **T3teedub** » 07 Jul 2007, 09:41

It may look like it's the original system on your van but rest assured your new one will look like that within about three years.

Post by **hammy44** » 09 Jul 2007, 17:13

got the cast iron piece fitted weather over here is diabolical could not get a dry day to work on it and need it for weekend so left it with mechanic to fix. £30 for his time sounds like money well spent as he had terrible time getting old one off so much so he told me not to bring it back. hope he;s only joking.