Tampa FL help request (on a trip) - welding

[vanis13]

On a trip visiting mom for a couple months. On way, Walker muffler 22392 (w. Lifetime NAPA warranty already warrantied a few times in the 15yrs I've had it) cracked and is not currently available anywhere even from other vendors and apperantly not at Walker either and no eta. Alternate ANSA manufacturer mounts differently and would require mods to muffler support on this 2.5 subi. (Had it pre-shipped to Mom's to discover this)....fwiw, the ANSA seems a better fit but it's only a 5yr warranty from AutoZone at $160 or 1yr from RockAuto at $90

Both mufflers are speced OEM Vanagon mufflers. Easiest solution would be to weld this up and replace when walker has back in stock if the weld fails.

The flex fitting on the header also failed - can either temp exhaust tape it or can get new flex fitting to re-weld.... It being a Vanagon on top of exhaust, it will likely take fiddling to get it right so a sambatista may be a better fit than a muffler shop. I can remove parts from van to allow for bench welding.

Thanks in advance. Am just N of Wesley Chapel which is about 45 min N of Tampa on 75

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83.5 Westy with Subaru 2.5, 4 spd manual, center seat, COLD A/C on 134a!, Winter camp heated with an Espar B4 gasoline furnace

www.SuperVanagon.com - some stuff I make

[danfromsyr]

if you can't find anyone closer and can limp to Tampa

maybe give Olsen's aircooled a call and see what/if they have any recommendations.


but a muffler shop should be able to pound in the next size smaller pipe and once cleaned give it a go at welding it up.

4902 N Florida Ave, Tampa, FL 33603
813-238-4226
http://www.olsensvw.net/
https://g.page/olsensvw?share
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[dobryan]

I would expect that a good muffler shop could weld that. Not Vanagon specific.
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Dave O
'87 Westy w/ 2010 Subaru EJ25 (Vanaru) and Peloquin TBD

"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson

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[danfromsyr]

honestly as for a replacement
I don't fret over warranty as I change them when they need changing. and doing a muffler warranty claim isn't worth my time..
it's a wear/consumable item.. change them as they require changing.
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[Sodo]

When you get that welded, add some braces from the flange to the crimp.
It doesn't take much bracing.
Three 1/4" rods from each side of the triangle to the muffler crimp will do it.
Flat bar is good too. But leave wrench access to the bolts.

All of the steel around that crack....is fatigued.
It's full of subsurface cracks.
Welding will re-melt some of them but not all of them.
You can be sure that there's a crack waiting to be the "next one".

Bracing that connection, such that there is "NO possible flex" would have been better in the beginning, but thats a case for 20/20 hindsight.
However..... bracing is imperative now that the steel there has been fatigued.
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'90 Westy EJ25, NEW oil rings (!) 2Peloquins, 3knobs, SyncroShop pressure-oiled pinion-bearing & GT mainshaft, filtered, cooled gearbox.
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered original gearbox
....KTMs, GasGas, SPOT mtb

[Vanagon Nut]

x2 on bracing. Making, welding, flat pieces between inlet flange and end of muffler body is not difficult. I have done this with angle grinder/cutoff and 110 VAC MIG. It's possible to weld on 3 braces and still leave room for wrench. For your situation, even one wide brace might suffice to get you home.

My Walker Quiet Flow muffler also did not have bracing at the inlet pipe. One reason why that muffler did not last long. IIRC, from the Ernst factory, both my Ernst 2.1 and 1.9 WBX mufflers had bracing on at least the inlet pipe.

I had no problem getting a NAPA shop to replace a flex joint on my engine conversion exhaust while on a trip. If there's room to get at that part on your exhaust, it can be done without too much trouble. IMO, it's worth getting a quality flex joint in there to prep for a new muffler.

Neil.
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1981 Westy DIY 15º ABA
(VW Gas I4)

1988 Westy DIY 50º ABA

VE7TBN