Classic cars forum & vehicle restoration.

Kelsham · Posted: Thu Feb 28, 2013 5:50 pm Post subject: XJ-S New straight exhaust pipe

Thought I would fit a new straight pipe to my XJ-S exhaust today as the sun was shining.

First problem was the two rear exhaust mountings kept slipping off the pins. Did it three times as I tried to trial fit the pipe.

Second problem the pattern pipe was just oversize and would not easily enter the exhaust box.

After several tries It was obvious it would need more than a quick clean up. I thoroughly cleaned the inside of the box and the outside of the pipe.

Then did it again and again as it still refused to enter fully. It was a sore trial climbing under the car so many times. My arthritis is considering its options as I write.

Eventually after some attention with a flap wheel it all seemed OK and I tightened it up, then realised it was hitting a bolt on the underside.

No amount of juggling about would realign it successfully.

Ended up removing the pipe complete with the exhaust box, I think I will need to remove half an inch from the straight pipe.

Last time I went underneath caught my head on the special subframe fitted to the cabriolet's Big cut on my head.

Wife asked me if I didn't think I might be getting to old to do such work, pretended to be astounded, privately I am beginning to wonder.

Looks like it might be colder day tomorrow perhaps I will stay indoors.

Regards kels.

Kelsham · Posted: Sun Mar 03, 2013 1:28 pm Post subject:

Well, I went back to it yesterday and with the pipe parted from the box I tried to polish up the two parts where they connect.

A good polish failed to improve the fit. eventually fitted a flap wheel to my grinder and removed small amounts of metal from the new pipe.

I had marked and measured the pipe before dismantling.

After several sessions with the flapwheel the pipe entered the box and I managed to slide it in twice as far as before.

No need to cut the pipe. It goes to show pattern parts can be a problem.

Then realised I had used up all the firegum, thank God.

Put the whole thing off till Monday or Tuesday.

regards Kels.

Rick · Site Admin Joined: 27 Apr 2005 Posts: 22438 Location: UK

Exhausts aren't much fun agreed. What model XJS do you have?

RJ
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Kelsham · Posted: Mon Mar 04, 2013 10:18 am Post subject:

1986 xj-s 5.3 vee twelve cabriolet.

regards Kels.

Kelsham · Posted: Tue Mar 05, 2013 5:07 pm Post subject:

another two hours wasted it seems the pattern part is just a few degrees out.
In spite of my best efforts the pipe insists on hitting the floor. I am beginning to contemplate action with the angle grinder and MIG.

Regards Kels.

Kelsham · Posted: Mon Apr 15, 2013 9:52 am Post subject:

Well I actually had the angle grinder in my hand before commonsense prevailed.
I took the pipe back off and realised that the olive that fits on the downpipe seemed a bit on the loose side.

I checked the old pipe and found the old olive was larger in diameter and width.
I removed it with a big hammer, well I needed to vent my frustration.

Assembled the pipes, perfect fit.

I now realise the olive is a new spare I had in stock and is meant for the exhaust box.

Kels.