Okay a couple months ago I took off my downpipe to have a flex section put on...well my buddy who welds put the flex section on the very end and the flange on the flex. I went to bolt it back up and forgot to take in account that the Star DPs flange is at an angle to the cat. Well now I have a nasty exhaust leak. Question is how do I get the right angle/ length to bolt up exactly to the stock cat? Do I need to take off the DP again? How do exhaust shops do it, do they cut and weld while the the pipe are on the car still? THanks

Measure, cut, and fit the pieces while the downpipe in installed. Tack-weld as you go, that way if you mess up you can easily break the tack-weld and fix it. Once it's all tacked together and complete, carefully remove the downpipe and butt-weld joints.

tip: unhook your battery first IMO

Using the flex section you can get a little play. But honestly the best way to do it is like Dougie said. Fit, Tack, weld.

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four nails four corners four riders and four horses

I had mine welded on the car. The guy that did it put it up on a lift and just stood under it and welded it. Very easy .... for him ... I don't weld.

1999 Eclipse GST 4G63

welding on the car can be a PITA....you have to keep the weld pool small to keep it from dripping on you or anything. what i do is just what dougie said, fit, tack then finish the welds with the exhaust off the car. that way i can heat it up with a torch and let it cool properly to ensure it welds easy and the welds are nice and strong

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96 Black ESi
91 Red TSI AWD (RIP)
02 WRX


"turnin wrenches for nine hours in the pouring rain, just to get the beast up and running again"

Aerospace Certified TIG welder for Precision Castparts in Portland, OR.

JoshSpair.com

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2012 2500HD LML