Need exhaust advise before I start cutting stuff...

[024rnrSport]

Got the two Magnaflow cats and the Walker Quietflow muffler/tail pipe. The male extension coming off the back cat will not go in the female flange on the muffler by about the wall thickness of the Magnaflow pipe. I believe the Magnaflow ID is the same as the expanded OD on the Walker. My only thought is to make slits in the male extension on the cat so it can collapse a little and hopefully go in far enough to get the flanges to come together and seal. Ideas?? I want to get this damn thing installed...

 

[19963.4lsr5]

With the proper tools you could remove 1/16" and see what happens. Or try two gaskets.


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[diverscale]

if you want the quick and cheap solution, grind off the male flange flush, and find a fitting gasket or use copper gasket maker between the flanges.

 

[024rnrSport]

With the proper tools you could remove 1/16" and see what happens. Or try two gaskets.


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Remove 1/16 from what? The extension is about 1/2" so I would need about 6 gaskets

 

[19963.4lsr5]

Remove 1/16 from what? The extension is about 1/2" so I would need about 6 gaskets

Ok remove an 1/8" for starters. Those gaskets are 1/8" thick. And a crushable metal gasket.


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[Chingpo05]

this type of gasket that is supposed to be used is the donut gasket. its a huge gasket that Honda's typically use and it seals a whole lot better.

 

[024rnrSport]

Thanks for the replies but let me clarify... it's not a length problem, it's a diameter problem. I'd prefer to keep some material instead of cutting it flat and merely using bolts to secure the two together.

 

[Srt4runner]

Thanks for the replies but let me clarify... it's not a length problem, it's a diameter problem. I'd prefer to keep some material instead of cutting it flat and merely using bolts to secure the two together.

I had this same issue on my 3rd gen. The male exhaust pipe that extends about a 1/2" past the flange ends up getting stuck on the exhaust pipe/welds that are inside the female flanged section, preventing the 2 exhaust pipe flanges from bolting together flush. Like others have said, you need to trim some material off the 1/2" exhaust pipe that extends past the flange. Once you do that, the exhaust flanges will bolt flush. Also purchase 2 or 3 of these gaskets to go inbetween the connection. More Information for WALKER 31374

I ended up trimming some of the pipe and using 2 of these gaskets together, I have had a leak free seal for a few years. I used an angle grinder with a metal cutting wheel if I remember correctly. A dremel will not be powerful enough.

 

[024rnrSport]

There we go... exact same issue as mine. I believe it to be the difference in manufacturer. Magnaflow sees a 2.5" pipe as an inner diameter measurement and Walker sees it as an outside diameter. The mindset between the two is probably "performance" vs "economy".

The male flange is stainless and hard as hell. I've got a good angle grinder and will probably do a little of both in shortening the flange and giving it a couple cuts to help it contract and slip into the recess of the muffler.

I'd like to know which piece is "correct" to the oem parts so I can tell at the offending company (like it would do any good...)

 

[19963.4lsr5]

Umm, my Napa cat back bolted right up no issues.


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[024rnrSport]

It's that cat that's the problem I think...

 

[19963.4lsr5]

It's that cat that's the problem I think...

Yea, my cat is factory. And for the 97 puppy hauler I bought a flange kit when it's time for a new exhaust. The PO cut off the Cat rear flange and stick welded a strait pipe on when the muffler was replaced. It looks ugly but works for now.......


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[024rnrSport]

Really hoped to avoid welding (ie... paying more money) to get this thing installed. Sucks that Magnaflow didn't take that into account so this can all just bolt together like it's supposed to.

 

[TheDurk]

Walker has it right. My new Quietflow bolted up to stock cat no problem.

 

[024rnrSport]

So after speaking to Magnaflow I think I've determined it's the Walker muffler flange that's the problem. Since my stock stuff is still on and will more than likely need to be cut to come off i can't say 100% forsure. Some of the reviews on the Walker say they had problems similar to mine and some say it fit perfectly... go figure.

The Magnaflow pipe is 2.5" OD and the Walker inlet is about 1/16 smaller. Pisses me off...

 

[024rnrSport]

By chance does anyone have a rear oem cat they can measure the rear extension flange? On the Walker site they list the muffler inlet as 2 1/4". A LOT of aggravation over 1/8"

 

[diverscale]

we already gave you a very viable solution. Why don'T you want to trim the extra material if both flanges and bolt pattern fit? Most exhausts holds only by those bolts and a gasket in between, it won't fall off or leak if installed correctly.

Aftermarket exhaust component are rarely 100% bolt-on, you have to deal with it.

 

[024rnrSport]

I am fully aware of how to make it work. I was just curious what the oem sizes were possibly to save someone else the frustration in the future when buying "direct fit" parts.