Help - Exhaust alignment

[bodmin]

Looking for some help on problem that's been annoying me for two years now.

After the engine drop on my 89 3.2 Carrera I replaced the heat exchangers, cross over pipe, and back box with new stainless items. The pre silencer pipe was already stainless so no need to replace this.

No matter how hard I tried I couldn't get the flange between the back box and pre silencer pipe to meet. There was always a 10mm stand off. I worked on it for hours trying various things, including trying to pull the gap together with long bolts, removing the rear hanger, but in the end I inserted an extra stainless flange with a gasket on each side to bridge the gap. This was the only way I could find to mount it keeping the rear box level and not pulled in at one side.

The extra flange works, but just doesn't look right. My OCD has now got the better of me, and I need to get this fixed.

Are there different lengths of pre silencer pipes available? The one I have is Dansk.

I can't find any information regarding anyone else having a similar problem.

Some pictures attached, last one showing the extra flange. Advice gratefully received.

[uwanna]

Originally Posted by bodmin

Looking for some help on problem that's been annoying me for two years now.

After the engine drop on my 89 3.2 Carrera I replaced the heat exchangers, cross over pipe, and back box with new stainless items. The pre silencer pipe was already stainless so no need to replace this.

No matter how hard I tried I couldn't get the flange between the back box and pre silencer pipe to meet. There was always a 10mm stand off. I worked on it for hours trying various things, including trying to pull the gap together with long bolts, removing the rear hanger, but in the end I inserted an extra stainless flange with a gasket on each side to bridge the gap. This was the only way I could find to mount it keeping the rear box level and not pulled in at one side.

I also installed a Dansk premuffler and a Dansk muffler. The only difference
is I used the larger Dansk premuffler versus the Dansk cat bypass pipe you used. However, I had exactly the same alignment problem you had, and solved it just as you did with an extra flange and gaskets. I couldn't see any other way to solve the problem. Perhaps Dansk has their measurement just a bit shy, just guessing.

[Flojo]

there are adapters in the WWW.
I just remeber it as I encountered a similar problem fitting the 2in/1out Danks 952 sport muffler to the SSI.
at the end I solved the problem by modifying the muffler for more clearance in its middle section towards the engine where it is seated to be fixed.

[bodmin]

Well it's actually great to see that others had had the same issue, and I'm not alone.

uwanna - great that we came up with the same solution.

I'm seriously thinking of removing the premuffler and getting a stainless exhaust specialist to cut it and extend it 10mm - assuming the correct diameter pipe can be found and it won't end up looking a mess. It will also be important that the flange is aligned correctly before welding to ensure that the bolt holes line up.

[uwanna]

Originally Posted by bodmin

Well it's actually great to see that others had had the same issue, and I'm not alone.

uwanna - great that we came up with the same solution.

I'm seriously thinking of removing the premuffler and getting a stainless exhaust specialist to cut it and extend it 10mm - assuming the correct diameter pipe can be found and it won't end up looking a mess. It will also be important that the flange is aligned correctly before welding to ensure that the bolt holes line up.

Don't know if I would go to that extreme. Your spacer fix looks very sanitary, and I
think the things you are suggesting have the potential to look much worse.
Just my $.02

[bodmin]

Just thought I would resurrect this thread to see if anyone else had had this problem?