Has any one else had a difficult time with mk1 exhausts?

[srgtlord]

So has anyone else had a difficult time replacing the entire mk1 exhaust system? I purchased an entire setup minus the downpipe for my cabriolet.  Exhaust arrived in 3 peices from bosal.With the clamps supplied from bosal and the clamps were too big... Soo I purchased some cheap american U clamps. I clamped the exhaust together and 2 weeks later it fell apart at the downpipe.... I only had enough room to emergency weld 3/4 of the pipe back together and slapped some sealant on the other 1/4. This held up for another week, then the clamp at the exhaust loosened up.... So to make a long story somewhat shorter I pulled the rear axle , ended up running new brake lines found out my manifold was cracked, ended up using a diesel manifold and a diesel downpipe plus some adapters to mate the downpipe to the rest of the car and welded the sucker together as 1 piece. Now the sucker waits to be put back together......

[bajacalal]

There's a reason exhaust shops weld instead of using u-clamps, it's because the clamps suck and welding it is usually pretty much permanent.

Especially on a vehicle that vibrates a lot, they're going to come loose.

Also, if you're still using the "spring clamps" that connect the downpipe to the "toilet bowl" where the exhaust pipe starts, they need to be replaced as well once they're worn out.

[745 turbogreasel]

U- clamps should be tightened  till they dent the pipe enough it seals when you  block the tailpipe.
Properly installed, they will hold for months even if you remove the clamps.
If you use an impact wrench, it takes seconds.
Occasionally,  uneven clamping will keep it from sealing,  add another clamp at a different angle.  Done.
Try not to point the threads  down where thy can get hit.

I usually weld my own stuff, because I like doing it,  but clamps  ought to hold fine till the pipe rusts through.

[hillfolk'r]

Or band clamps are nice im usin em on sooty. A flex pipe is mandatory and older mk1s had a support brace on he pipe back where it goes over the axle. The oe clamps are good. I dont like the us clamps cause they are bulky

[shwak23]

Yeah the audi style band clamps work well. You could even tack weld it together and follow up with one of those clamps. I hate exhaust. Exhaust shops really don't charge that much and they will do it right and if it clunks or bangs around you can take it back and complain. (Granted I am about as poor as they come so my exhaust is pieced together by me and it vibrates off the rear axle at idle like a motha***a.

Sent from Outer Space!