Hi all.

A 500 KM + test run in my VanaJetta yielded 2 cracks in my exhaust.
Ironically, one where the pro welded. I think me modifying the 90*
bend to fit didn't help. Though I annealed it before bending it more,
I'm sure I hardened the metal more in the process (it was cold
rolled).

Pics:

http://tubaneil.googlepages.com/tempexhaustcracks

"S" and "E" show where I think one crack started/ended. The other is
along ~ 1/4 of bottom part of weld where pipe meets flange. It's hard
to capture in photo. Of note, the gasket at this flange is now leaking
too.

What's the best way to repair this?

Remove it, go to exhaust shop and have them fabricate or patch/fix
this? Could they get the angles/dimensions the same? I assume bringing
in the vehicle would be best.

I know a redesign of the primaries/collector is warranted, but I
really don't want to allocate time to doing this myself. I can't
imagine what a custom shop would charge for this.

I could try to repair it myself, but the cracks are in a tight "space"
and the flange is thicker than my welder will handle. I guess I could
grind down the weld at the flange, reweld, and then patch the crack on
the pipe itself. Suggestions are more than welcome on this procedure.

I need this area to be supa strong, and I'm not so trusting that an
exhaust shop would get this aspect right, so listers experience is
most welcome.

Neil.

--
Neil Nicholson '81 JettaWesty "Jaco
http://groups.google.com/group/vanagons-with-vw-inline-4-cylinder-gas-engines
http://web.mac.com/tubaneil
http://tubaneil.googlepages.com/