I wasn't going to answer this, but it is Saturday evening and not too much
else to do.  One thing I learned on US cars many years ago was that when you
do muffler/header/tailpipe work, you do the whole thing.  I have done the
whole thing on my '84 and it is much easier when you can take lots of things
off such (if I remember correctly) muffler heat shield and work just on the
headers without being in such tight quarters.  Also, Sears used to sell some
"cut-down" 13 mm open-end wrenches that are great for putting nuts on the
studs.

John
'84 Vanagon
----- Original Message -----
From: "Dennis Haynes" <dhaynes@OPTONLINE.NET>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Saturday, August 13, 2005 10:09 PM
Subject: Re: 1.9 exhaust install

> If you're going to pay anyone, you want an experienced mechanic, working
> on these beasts, and knowing how to use real torches and drilling out
> broken studs. The chain muffler place is not the right choice. Be
> prepare to also replace the collector pipe. Trying to save this may cost
> more in labor than the pipe is worth. Makes sure all the muffler and
> j-pipe supports are there, correctly or else the new pipes will soon
> crack. Try removing the pipes your self. You may get lucky. If you can
> get sockets and wrenches to grab, do not force too hard. This is when
> proper use of the torch will save the day. Once a stud or bolt is
> broken, the next possibility is MIG welding a nut onto the stud and the
> heating of that will usually get the offending stud to turn out. Last
> resort is drilling and Heli-coils.
>
> Dennis
>
> -----Original Message-----
> From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf
> Of Ed
> Sent: Saturday, August 13, 2005 4:05 PM
> To: vanagon@GERRY.VANAGON.COM
> Subject: 1.9 exhaust install
>
> I was a little afraid to tackle installing the header pipes (all that it
> needs and all I can afford right now) on my '85 Westfalia, so I took it
> for three estimates at the big chain muffler shops. I have the headers
> and all the gaskets and hardware. I wanted to gat estimates just for
> installation.The cheapest said $100 to $150 after looking at it, one
> said around $150 after only looking on their computer. The most
> expensive was $150 to $200.
>
> These estimates are enough to make me try doing it myself, but what am I
> up against? What is likely going to be the hardest part? Getting the old
> nuts and bolts off? Getting the studs out of the header? I don't want to
> mess anything up and then have to drive it so somplace to have someone
> else do it anyway. Sometimes I'm hesitant to do a job and then wish I
> had tried after paying the bill; sometimes it's not as bad as I had
> thought, like the power steering rack I did this spring- that was pretty
> straightforward.
>
> I'm not sure how much I trust some of these muffler places, but I
> thought they might be cheaper for labor. Some of their labor rates are
> more than a full mechanic.
>
> Any advice if I try to do the two header pipes myself?
>
> Thanks,
> Ed
>