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[Greenbay packer]

I'm going to have to replace the exhaust on my 2.5 V6 but the downpipe flanges are totally knackered.  I don't want to have to replace the cats and can't see any advertised on here.  Does anyone know if a repair section, flexi section or replacement flanges are available for this - in the US they seem to sell bolt on split flanges which look ideal, but I can't find anyone in the UK that sells them.  Also, does anyone know the diameter of the pipe at the end of the downpipe where the flange sits?  Is my only option to replace downpipe and cats  ?  Thanks for any advice given.

[biggriffin]

The flanges on the downpipes' knackers? If you mean the bolts that thread in to them, just drill em out, replace with nuts n bolts. Never yet seen flanges on a car be beyond use,

[Greenbay packer]

The flanges on the downpipes' knackers? If you mean the bolts that thread in to them, just drill em out, replace with nuts n bolts. Never yet seen flanges on a car be beyond use,

I wish it was just the bolts, but the flanges are very bad too and the bolt holes through them aren't likely to survive even if the rest does.  If I can find out how to do it I might post a picture of them.

[tunnie]

They can look totally knackered but they will survive, you will probably end up drilling the gits. Try soaking them in plus gas few days before, thay plus heating up & cooling down can help

[biggriffin]

The flanges on the downpipes' knackers? If you mean the bolts that thread in to them, just drill em out, replace with nuts n bolts. Never yet seen flanges on a car be beyond use,

I wish it was just the bolts, but the flanges are very bad too and the bolt holes through them aren't likely to survive even if the rest does.  If I can find out how to do it I might post a picture of them.

Read the how to guide in the welcome area.

[Diamond Black Geezer]

I had to get new flanges welded on mine. Sadly now, only a few months into her being on the road there's a rattle coming from one of the Cats occasionally on idle, but that's another story

Basically method was to take my old exhaust (which was like a colander soaked in brine for a year, then machine-gunned  ), and chop the flanges off, then split the flange, so like two letter 'C's, then weld it on the cat (after removing the old flange, of course)

I hasten to add it was not me who did this but a very good and skilful mate. 

[Greenbay packer]

Basically method was to take my old exhaust (which was like a colander soaked in brine for a year, then machine-gunned  ), and chop the flanges off, then split the flange, so like two letter 'C's, then weld it on the cat (after removing the old flange, of course)

I hasten to add it was not me who did this but a very good and skilful mate. 

Thanks for this info, it sounds like just what I'll need to get done to my downpipes.  Was your mate able to do this with the pipes in situ or were the downpipes removed so the weld could go all the way round? 

[biggriffin]

Silly time.
Do you mean the cast flange with the bolts thro--or the end of the down-pipe which goes up to the centre section.,as the down-pipe end normally just needs a little wire brushing and a bit of sealent.

[Greenbay packer]

Just learnt how to add photos (I hope!).

This is the bit I mean, the downpipe flange is at the bottom and centre section of exhaust at the top:

The photo isn't at the best angle to show how bad it is, but one bolt has rusted away and a lot of metal is missing from the flange itself - at least one bolt hole is unlikely to survive any attempt to replace the bolt once I've disturbed the exhaust centre section.  Other side is almost as bad.  May try getting a pair of these split flanges from the US: http://www.ebay.com/itm/2-1-4-2-25-Exhaust-Repair-oval-SPLIT-FLANGE-flat-2-slotted-hole-FX08SP-/181582662810     (I know this 2.25" one is the wrong size) .  Otherwise I'll see if I can get some welding done as suggested by Diamond Black Geezer

[biggriffin]

Clean them up first, they,just look a bit rough.,new nuts n bolts and washers and a good dollop of fire gum
 

[swordfish]

  yep well serviceable them,, they look worse than they are  send them up to me and i will sort them for you