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02passatw8 View Drop Down
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  Quote 02passatw8 Quote  Post ReplyReply Direct Link To This Post Topic: Flex Pipe
    Posted: 26-Dec-2011 at 06:23
Well sounds like I have an exhaust leak coming from the flex pipe. Which makes sense from being in the salt and all the snow and ice in NY. The whole pipe is 190 a side. ECS has the universal flex pipes made by ANSA for about 25 a piece. My question is the exhaust is 2.25" correct? and if anyone has any other suggestions Im open to them.

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mperew8 View Drop Down
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  Quote mperew8 Quote  Post ReplyReply Direct Link To This Post Posted: 27-Dec-2011 at 05:15
Find a place that does custom exhaust work, there are places in Northeastern Pa that would do everything from the car back for between $200 to $300, its fairly easy to work on as exhausts go ( at least from the cat back) and you may be able to pay a little more to get stainless.

-2004 W8 6spd Silverstone Grey.
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  Quote GS535i Quote  Post ReplyReply Direct Link To This Post Posted: 27-Dec-2011 at 13:10

With one fractured flex joint, and the other on the way, I purchased two 2.25" X 6" triple weave joints on ebay ( $31 delivered to the door - stunningly cheap IMHO) ..... and and them TIG welded in.

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02passatw8 View Drop Down
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  Quote 02passatw8 Quote  Post ReplyReply Direct Link To This Post Posted: 27-Dec-2011 at 16:18
How was it removing those exhaust pipes? Did you get 2.25 ID and they just slide over the stock pipe and you welded it?
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  Quote mperew8 Quote  Post ReplyReply Direct Link To This Post Posted: 27-Dec-2011 at 16:41
Mine sucked to get out, needed a torch to heat them up before the bolts would break, one snapped and I had to drill it out and fit a new bolt and nut on.

-2004 W8 6spd Silverstone Grey.
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  Quote 02passatw8 Quote  Post ReplyReply Direct Link To This Post Posted: 27-Dec-2011 at 18:51
I will take a look at it thursday. If I can replace the flex pipe without removing it i will, but i believe it will be a pain to weld it while on the vehicle. The rest of the exhaust is perfect, Hate to start pulling everything apart unless needed.
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  Quote mperew8 Quote  Post ReplyReply Direct Link To This Post Posted: 27-Dec-2011 at 18:55
Once you break the 6 bolts to the cats its really east to drop the rest of the exhaust, just have a buddy to help its awkward to move.

-2004 W8 6spd Silverstone Grey.
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  Quote GS535i Quote  Post ReplyReply Direct Link To This Post Posted: 27-Dec-2011 at 22:24
At the flex joint, the pipe OD is 55mm (= 2.16"). 2.25" ID is generally the closest available, as metric sized fittings are (too) rare on this side of the Atlantic. TIG welding required a stick as a filler for the gap .... MIG would be easier, and likely the only choice if doing it on the car [disconnect the battery if doing so!]

Regardless, far better to remove the down pipe and do the flex on the ground: I used a zip wheel on a grinder to snap off the coupler before the resonator, and replaced it with new .... easier than fighting with one if corroded on.
03 Variant W8 silver on black TIP
00 Variant white 1.8T 5sp
96 993 C4S midnight blue/cashmere
90 535i blk/blk 5sp
928 5sp
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  Quote joe01952 Quote  Post ReplyReply Direct Link To This Post Posted: 13-Jan-2012 at 14:58
Hi
Have any of you guys gotten a real loud almost like the pipe came loose sound around the flex pipe, then it seems to quite down, not sure it its as quite as it should be.. Just strange how it hgot louder then quieter?? Flex Pipe?
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