In a message dated 8/9/2002 3:34:29 PM Eastern Daylight Time, 
LISTSERV@GERRY.VANAGON.COM writes:

> Could some one please tell me what the cheapest way out is on replacing the 
> exaust system on my '87 Vanagon? 

       Cheapest is not always the best.  You gotta figure what you want.  My 
suggestion is invest the money in the system that will last the longest and 
not have to be bothered with again.  These conditions can be met by using the 
<A HREF="http://members.aol.com/Fkc43/stebro.htm">STEBRO/Vanagon Stainless Steel Muffler & J-pipe</A> which I sell and the DANSK 
stainless steel headers from <A HREF="http://www.busdepot.com/">The Bus Depot - Discount VW Parts</A>.  The CAT if 
you need it can be obtained from most any good auto parts or the Bus Depot. 
The cast iron collector piece if needed can be obtained at the Bus Depot. If 
using your old cast iron collector piece make sure all three of the mating 
surfaces are clean and flat.  See the STEBRO/Vanagon site for customer 
comments on price comparisons.
        When you do this project I highly recommend you replace all eight of 
the head flange bolt/studs with stainless steel hardware using bolts of the 
proper length at all locations and installing heilicoils or time-serts in all 
eight of the head exhaust port flange connections.  It will be much easier to 
do this job by dropping the engine as the rear exhaust port connection on the 
heads are impossible to work on with the engine in place.  Make sure the bolt 
holes in the header flanges are one size larger than the bolts so there will 
be no lateral stress on the flange joint. This would be also the time to 
check the condition of the engine push rod tins and replace or repair them as 
necessary as they connect to the exhaust port flange lower bolts.  Make sure 
all mating surfaces are clean and flat.  Use Permatex or Loctite RTV, high 
temperature head gasket sealant on all gaskets.  Header gaskets, metal side 
toward the head.  Doughnut gaskets, make sure the bevel in the CAT's both 
ends is there if not create it with a rotary tool, use the sealant here also. 
 There is more info regarding the use of the doughnut gasket on the 
STEBRO/Vanagon website. When installing the system do not tighten any of the 
connections until you have the entire system in place, then slowly tighten 
all the connections so that there is no undue stress on any one of the 
connections.  Hope this helps !

Cheers��

Frank Condelli
Almonte, Ontario, Canada
<A HREF="http://members.aol.com/BusFusion/bfhome.htm">BusFusion</A> a VW Camper camping event, Almonte, ON, June 2003
'87 Westy & Lionel Trains
Member: <A HREF="http://www.vanagon.com/">Vanagon List</A>, <A HREF="http://www.bcn.net/~limbo/">LiMBO</A>, <A HREF="http://www.westfalia.qc.ca/">IWCCC</A> & Capital City VW Club 
Vanagon/Vanagon Westfalia Service in the Ottawa Valley
<A HREF="http://members.aol.com/Fkc43/stebro.htm">STEBRO/Vanagon Stainless Steel Mufflers</A> �
<A HREF="http://members.aol.com/Fkc43/busindex.html">Frank Condelli & Associates</A> or http://frankcondelli.com