Exhaust Pipe

The instructions for installing the exhaust pipe are only three steps on one sheet, but the task took me a solid 4 hours to complete because I was trying to be careful. The installation of swept tail pipe requires removal of the stock straight pipe, which is welded in place on the muffler.

Stock straight pipe

I curtained off the area since the cutting and grinding wheels produce a lot of dust

Prepped for surgery

Tools for the job included an angle grinder with a 5” cutoff wheel, a grinding wheel, and flap sanding wheel. I also needed a rotary tool with a metal cutting wheel, sanding drum, and sanding foam.

The straight pipe is attached really well. The instructions say to grind off the weld that exists between the pipe and a shroud, however that weld was quite deep. At first I was grinding very carefully so as to remove as little metal as possible. Eventually though I realized there was no going back, so I started cutting a bit more liberally.

My first attempt to grind off the weld – it’s still attached very well

The instructions say to cut off the straight pipe, leaving 32.4mm (1.25”) exposed. That means the portion of pipe that needs to be cut is underneath the shroud, so I couldn’t use a standard 5” cutting wheel to cut the pipe, otherwise I’d be cutting the shroud too (which is needed to support the new tail pipe). So, after I cut off the pipe after the shroud, I switched to a Dremel tool with a smaller cutting wheel and made the surgical cut from the inside of the pipe, while laying down on my back.

Cutting off the portion of the pipe after the shroud, so that I’d have access to the portion before the shroud
Finally cut through the pipe, but this piece was still stubbornly hanging onto the shroud
I cut off a little bit of the shroud and finally I could remove the remaining piece of the old pipe
Fitting the inner clamp was a tight fit, I had to use a screwdriver and hammer to tap it past the shroud
New tail pipe and clamp in place
Fit looks good
Clamps installed, seems to be held in place pretty well
Cutoff wheels tend to produce quite a bit of dust, leaving me with raccoon eyes after I took off my safety glasses and face mask!

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