Exhuast problem -new member looking for help!

Post by **Reco** » 29 Oct 2007, 15:08

Hello all - am in need of advice to solve following exhaust problem:

I have a SS exhaust from JP's which keeps cracking manifolds. Jp have been very helpful and currently think its due to excessive strain as brackets weren't fitted to support pipes running laterally across the engine (between cyls 1&3 and 2&4).
JP system is designed to fit to original brackets but I assume these were knackered when exhaust fitted.

It seems I can't buy new brackets as have no part no. short of buying new mild steel manifolds they are supplied with.

Have contacted CJ for secondhand ones but he had none.

Any one got any spares or ideas?

I understand CJ's SS exhaust comes complete with brackets to suit -so anyone that has fitted one of his systems may have originals laying about on old exhaust?

I can't be only one experienced this problem - lots had JP exhausts fitted some time back -is yours fitted with originals or anyone know of suitable 'diy bodge' to do the job?

Sorry for long winded details but getting a bit desperate to solve this after 2-3 years of hassle and re-fitting expenses!

Cheers

Post by **syncroandy** » 29 Oct 2007, 19:09

I have a 2.1 JP system, the brackets I think you are referring to came with the system, basically they are just clips that support the side-to-side tubes. Something similar could be made up locally.

The only problem I've had, is the bracing rods welded from each flange down across the bend in the header, tend to snap off. One of them took a chunk of the header tube with it, I patched it with a bit of drinks can and a jubilee clip and while later got around to letting JP know about the problem and they replaced the part.

Post by **Reco** » 29 Oct 2007, 19:36

Thanks for that.
This is same 2.1 system, but did not come with brackets so will get back to JP although they said was vw part, -or as you say make something up.

I was hoping to find originals so can determine where to fix bracket between cyls 1 & 3 (have found that bracket between clys 2 & 4 goes to silencer support bracket).

I've also had brken struts across pipe bend -all of them to date and still off headers 2,3 and 4; plus brken stud (cyl 1) 2 weeks after fitting, then repair (smaller dia stud) broke; cyl 3 header broke twice now, and 'Y' branch where clys 2 & 4 join the rest welds are cracked:shock: - but to look on bright side I'm hoping this will give a bit of flexibility to the system!

Cheers,

Post by **HarryMann** » 29 Oct 2007, 22:09

Blimey, thats a sorry tale...

I've seen some US systems made with 14 swg tube for Vanagons - now I know why!

Post by **andysimpson** » 29 Oct 2007, 22:11

Mine unkown stainless system cracks head no 1 every few months, if welded just goes somewhere else, this is a common fault on all vw flat fours with stainless exhausts.

Post by **Reco** » 29 Oct 2007, 22:23

Thats the edited version of a very long story!
Jp have supplied 2 further sets of manifolds (bless 'em) but am now working my way through the bits left over. They say they've had no other problems.
As for breaking every few months - thats cheered me up as mine seems to go six months before breaking!

Post by **Reco** » 29 Oct 2007, 22:35

Anyone know where best place to put support bracket between clys 1 & 3?

I'll fit something up this time but when it goes again I think best option is to replace manifolds with off shelf mild steel and try to match up to the nice shiny SS box.

Good talking to you all.

Some great info on the site. Was a member before several years ago but computer probs banjaxed things for a while.

Cheers,

Post by **Ye Olde Syncrospares** » 30 Oct 2007, 08:34

my black syncro has a full stainless exhaust from a swedish maker and is held together with big springs like motorcross bikes,cj.

Post by **Reco** » 30 Oct 2007, 11:12

Hmmmm - springs, 14 swg tubing, regularly cracking headers " common fault on flat fours with stainless" - message seems clear.

Wish I hadn't bothered an just fitted standard system...you try to go the extra mile...

Wonder if its mainly syncros with probs?

Post by **Ye Olde Syncrospares** » 30 Oct 2007, 17:23

no just rubbish exhausts.

Post by **Reco** » 30 Oct 2007, 18:00

cj - I don't think you made 'em when I bought this one else I'd have got one!

BUT...re brackets have spoke to someone else at JPs today and they should have sent support brackets with system! all becoming clear.
Anyway new ones in the post and I should be able to sort this at last.

And what have I learned after 2-3 years hassle?
Brackets essential to ss exhausts, and to make sure they're supplied with any new system and fitted!

Cheers all

Post by **andysimpson** » 30 Oct 2007, 22:18

Reco wrote:Hmmmm - springs, 14 swg tubing, regularly cracking headers " common fault on flat fours with stainless" - message seems clear.

Wish I hadn't bothered an just fitted standard system...you try to go the extra mile...

Wonder if its mainly syncros with probs?

No all flat fours. there is lots of engine exspansion between pipes and stainless goes brittle so cracks easy.

Post by **Ray** » 30 Oct 2007, 22:45

I have a JP stainless on my syncro. Rear supplied support strap broke recently and I didn't fit the other bracket between 1 & 3 because the vw engine attachment was missing. Its been on for over two years and on a replacement engine for the last year. No problems encountered but maybe after reading this I should get the brackets fitted?

Post by **Reco** » 31 Oct 2007, 15:05

If you've had no trouble but strap only broke recently then you might now -deffo fit them! not worth risking it for a tuppenny-hapenny bit-JP should supply new one no probs.

Andy - But yours manages to break repeatedly despite having straps?

I should get and fit straps tomorrow -might be able to drive without one ear cocked for blowing!

Post by **Reco** » 05 Nov 2007, 14:47

Deffo no fittings beneath engine on my van for support bracket between clys 1 & 3.
There's obviously several vans out there that this bracket does not fit - which is a worry given the importance JPs attaches to these for long term trouble free system.
P'haps they should produce an alternative support bracket?

Meanwhile have fitted rear support bracket and 'Y'branch beneath cyl 2 has gone completely now (was cracked for some time) Bugger!