Exhausting Pipes (Day 197)

 The other day the sun came out.  This is a very strange occurrence at this time of year in the UK.  So I took the opportunity of experimenting on an exhaust pipe (muffler) dissection.  My exhaust pipes are shot (see: Exhaust Pipes Removed) and there is not much to loose by cutting them up.  I bought another identical set which are in much better condition but still have a baffle loose inside.  So I want to find out if there is any possibility of cutting into to them, fixing them up inside then putting them back together again.  I have seen on the forums how you can cut into a petrol tank and then braze the patch back in.  I have yet to find someone to do this for me but I thought I could a least start the cutting up process.  This was the idea:

This was the lovely day.

And this is one of the rubbish pipes.

So I starting cutting.

Dremel didn't last long.

But I did make a start.

This was what was rattling inside.

And this little critter obviously couldn't find his way out.

I need bigger tools.  Don't we all.

Another set of pipes (Day 157)

Purchased another set up pipes which arrived today from a UK supplier.  They are in better shape than my originals.  They have no scratches or road rash.  Very little surface rusting.  One of the silencers has a rattling baffle.  I think I am becoming a collector. (click image to enlarge)

 

Exhaust Pipes Removed (Day 57)

 So since the exhaust bolts are now out it was quite simple getting the whole system to come off.  But it doesn't look like it's in good shape.  One side is rattling badly (rusted internal baffles?) and both side let lose a load of powdered rust when I turned them over.

On the under side of both silencers there was blistering which had completely penetrated the outer skins.

 Very rusted underside.

Exhaust Pipes Examination (Day 56)

 This is what the pipes look like before removal.

 Don't think this is OEM

 

Exhaust Bolts OUT! (Day 55)

Big celebration here; we finally got them out.  All 8 of them and not a single breakage.  I think I have discovered the secret:

1.  Trick - take your time.  My bolts had been in for at least 25 years and it has taken me 2 weeks to get them out.  Not 2 weeks of total work but a little bit every day.

2.  I think the magic formula was a concoction of 50% brake fluid and 50% cellulose thinners.  Brush this on twice a day.  Mine came out after 3 days of this.

3.  Don't be afraid to do some impact driving.  I had hex bolts holding my exhaust in and it took me a while to find the right combination of driver bits and 3/8th inch and 1/2 inch converters.  Give them a good whack.  Do it a couple of times a day.  Keep adding concoction.

4.  Don't stick on the one bolt, try them all.  I spent the first week on one bolt.  Nothing moved.  Then today I tried another bolt on the other side of the engine.  It came out quite easily.  So I did some of the others.  The first bolt was the worst.  See the photos and you understand why.  I had spent all that time being put off because the first bolt I tried was the worst.

5.  Take your time.  Don't expect to do it in a day.

6.  My next trick was going to be the blow torch (I ordered them from Ebay but they have'nt arrived yet) but in the end they weren't needed. 

7.  Trick - try tightening them as well as unscrewing them.  My first discernable movement on the first bolt I got out was when I screwed it in.  Even the smallest movement is good.  Add more concoction and keeping screwing it up (until it's very tight) and then unscrewing it a little.  For a time it seemed to me that it got tighter the more I unscrewed it.  That was the sign to screw it back in and add some more concoction and wait a little.

8.  From the photos you can see that the concoction penetrated the bolts by about 50% (see the darker part of the bolt) which is quite amazing.