send it back or repair this one.
aftermarket parts .................especially exhaust parts - I've seen too
many that were faulty right out of the box.
New OE cat is prohibitively expensive of course.
I'd say either have a welder finish welding it properly, or send it back.
And, since there's some chance the next new one could be poorly made too,
I'd opt for getting this one fixed, either on the van if it's easy to access
the spot, or take the cat by itself to a good welder.
there's a small chance the leak will rust shut, but that's not the right way
to start out with a new part.
Scott

----- Original Message -----
From: "George Wietor" <wietorg@YAHOO.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Wednesday, October 15, 2008 10:24 AM
Subject: More Catalytic Converter questions

> Just installed a new Bosal cat delivered from one of our listmember
> suppliers. Adjusted the muffler supports to help everything line up
> better, installed a new muff and replaced the straps. Fired it up and felt
> some leakage. Strangely, it came from the base of the O2 sensor boss.
> Since the system was still cold, water was leaking from what appears to be
> a small flaw in the weld. Is this a significant problem?
> Keep it or send it back?
> TIA. George in Grand Rapids '87 Van O'White stock 2.1 L. Primping for the
> Re-Birthday party.