Exhaust install help

[rastasquid]

So my truck currently has an exhaust wherein the midpipe is welded to the third cat. Said exhaust drones, and I’m replacing with a GM Borla system. Anyone care to chime in with opinion as to whether I can clean up the cat enough to install the borla system with a factory clamp? Or will I need to weld the borla on? Pic for reference. Thanks!

 

[durandetto]

It might be possible but it won't be easy. The weld is on the sealing surface. So it would take some delicate cutting and grinding. Worst case you would have to take it to an exhaust shop and have it welded on. Still beats buying that cat pipe.

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[rastasquid]

The borla warranty will be voided if I weld it, although I’m not sure I’ll ever need that warranty it would be nice to have it. I was hoping to install myself but I don’t want to mess w it if it’s unlikely I’ll get it to install without welding

[rastasquid]

Or maybe I could used a band clamp? Any chance it’ll seal over that flare? I’m guessing not.

[Jaychevy81]

I had a issue with mine on the factory pipe without weld getting it to seal. I had to use a exhaust sealer to get it not to leak. I would try cutting it in front of the weld then grind back to the clam.


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[rastasquid]

That’s why the current pipe is welded, it wouldn’t seal with the clamp. Now, however I want to replace it and I’d rather not have to have it welded so I’m looking for creative ideas.

[durandetto]

Cut both flares off and sleeve it. Won't look pretty but it will work.

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[nominion]

I would cut the pipe just after the weld (mid pipe side) and remove the Y pipe from the truck. With it off, you should be able to use a grinder to clean up the weld enough to get the new catback exhaust to seal. 

[davester]

I would consider cutting the exhaust pipe there so you are installing the new exhaust over a short section of the old exhaust tube.  Ie, cut the exhaust about 2" up the tube from where the cat. is welded to the tube.  Then you have a decent, smooth pipe to clamp onto.  Or cut the output pipe off the cat (at the smaller diameter weld), and weld a new output pipe/adapter provide a new smooth pipe to clamp onto.

[rastasquid]

Follow up for anyone who cares, ended up having exhaust flanges welded to the midpipe and the cat, so that the system could be bolted in and removed if necessary. I’ll post some pics when it’s daylight for reference in case anyone else ever searches for a similar question. There’s no way in hindsight that the exhaust ever would have sealed properly with the factory clamp after grinding down that weld I had in there.