Replacing the centre section of the exhaust.

[Jocko]

My exhaust has started to blow (a month from its MOT!) so I am going to have to replace it. Any tips or tricks from the guys who had done it before?

[guest1372]

The bolts on the cat flange might be a pain, had to cut mine; flange itself is pretty rusty.  Make sure rear joint stays flexible.  Might have to bend hangers on aftermarket units to get best fit.
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TG

[Jocko]

Once you cut the nuts off, can you punch the remains out of the cat flange, or did you have to drill them out?

[RichardA]

Might have to bend hangers on aftermarket units to get best fit.
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TG

This. My aftermarket replacement centre section started rubbing against the body, local independent garage who fitted it sorted it out for free.

[guest1372]

Access was not great - had to use hacksaw blade held with glove for one of them, O2 sensor nearby so heating nut head with gas could catch the wiring, studs/bolts came out without problem.  Replaced with stainless bolts/washers as rusty cat flange in very marginal condition so it's possible the joint may need to be unbolted.  Also used a lot of paste due to the rather iffy cat flange. 

Only reason I did the job was because the garage wanted to change the cat due to the flange.
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TG

[Jocko]

Plan is to grind the nuts off and punch out the studs. Might be a better plan to grind through the pipe to to allow me to remove centre section and get better access to the nuts for the pneumatic gun.
Got the new centre section today. Bosal exhaust and both gaskets for the princely sum, including VAT, of £25.58. Not too sore.

[guest6436]

[Jocko]

I had considered that, but after inspection it is well passed the Gun Gum stage.