> my exhaust system is gone..so my mechanic wants $1200 to 
> replace the whole thing..including catalytic converter, 
> muffler and all pipes...busdepot has it all for about $550.00 
> on the parts...not being to mechanically inclined, is this a 
> good project to do myself? any secrets to succcess?

Installation is relatively straightforward, but removing the old parts can
sometimes be difficult.  Exhaust nuts have a tendancy to seize due to a
combination of rust and prolonged exposure to heat, making them challenging
to remove. The same can apply to the 02 sensor, although you can always just
replace it while you're there, which will avoid that issue. You may need a
good penetrating oil such as Kroil, or a small torch, to help get the old
setup off.  Or maybe not; you won't know until you try. At that point,
bolting the new stuff up isn't that hard, since you're replacing everything
at once (It can be more difficult if you're trying to re-use some of the old
pipes, as they may be tweaked and won't easily mate to the new ones.
Replacing everything at once is easier.)

As another alternative, you could see what a local muffler shop will charge
to install the parts if you supply them. While the Vanagon exhaust system is
somewhat convoluted compared to most, the actual installation process isn't
really that different from what a muffler shop is used to doing.  It's not
like they're going to have to bleed the coolant system or something that
absolutely necessitates Vanagon expertise.  Basically it's just a matter of
hanging the exhaust and getting the connections tight, and they're used to
dealing with seized exhaust nuts. I have often found that muffler shops will
do this sort of work as well as, but cheaper than, VW specialists.  Of
course, like any other repair shop, both the price and quality of
workmanship can vary from one to the next.

- Ron Salmon
  The Bus Depot, Inc.
  www.busdepot.com
  (215)  234-VWVW

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