Problems attaching new straight mid section exhaust

[FONT=Arial, sans-serif]Hi Guys,[/FONT]

[FONT=Arial, sans-serif]I am replacing my busted mid section exhaust on my 1997 Defender 300tdi 110 CSW with a straight through pipe. [/FONT][FONT=Arial, sans-serif]
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[FONT=Arial, sans-serif]There are 2 bolts attached/welded to a ring shaped bracket on the cat downpipe side, which attach to the ring shaped bracket on the new mid pipe that has 2 holes to accept these bolts and is tightened with two nuts (ordered from Paddock). Simple job you say.[/FONT]

[FONT=Arial, sans-serif]One of the fixed bolts on the attaching bracket of the cat downpipe side will not accept a nut, where it has possibly cross threaded or rusted, meaning I cannot connect the new mid pipe exhaust to the front downpipe. I have temporarily fixed the two parts with twisted wire which is not ideal.
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[FONT=Arial, sans-serif]Are there any tips to getting the nut screwed on to this fixed bracket bolt to tighten or can I get some component to attach the two exhaust pipes bypassing these brackets?[/FONT]

[FONT=Arial, sans-serif]Thanks for any advice.
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[FONT=Arial, sans-serif]DD
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not 100% with you here, are they deffo welded on and not just rusted on bolts?

also, what about cutting them off and drilling two holes and fitting normal nut an bolt?

Thanks for your quick reply

I must state firstly that I am a novice to mechanical work

They seem pretty firmly in place. If I knew they were removable I would hit it a slap with a hammer and replace with new bolts but I don't want to damage them if they are firmly welded.
I could do as you say but am lying on my back underneath, in a confined space and with limited tools, and wondered if there was a clamp I could just fit or a clever way to attach just this one nut!

yes they are welded onto the original cat downpipe (mine were anyhoo)
options are,
get the nut to fit.

remove downpipe, cut off the old stud, and drill.

and I have seen repair flanges that bolt round, so you could cut off the flange with the integral bolt, and use a repair flange.

also knows as a split flange

snigger....

Top man timtheenchanteruk Thats exactly what I need. Saves me having to invent something.
I just don't fancy removing the downpipe or feckin' around on the ground under the Defender with drills etc for hours for what should have been a quick 30min job. Will have a look now on Paddock or Britparts.

Regards DD

Paddocks have never heard of exhaust split flanges and don't stock them. They recommend an exhaust specialist. Trawled the internet for hours and could only find two companies doing these.

First: Nickson Industries, Inc. 336 Woodford Ave. Plainville, CT 06062

https://dl.dropboxusercontent.com/u/59935596/Flipbook Retail/Retail Catalog.html

Page 12, ni number 17177

Don't know if they deliver to the UK though

Second:Walker Exhaust Flange Repair

Amazon.com: Walker 31884 Exhaust Flange Repair Kit: Automotive

They do not have the correct size

There was nothing on eBay either

Anyone know where I could find an exhaust split flange anywhere else?

Why is it that the apparently simple jobs always end up being the most difficult

Regards DD

i'm unsure about the new mot cat rules and if you'd get away with it, but a new straight through replacement cat section is only 15quid or so.

cats aren't needed on old ****

trax said:

i'm unsure about the new mot cat rules and if you'd get away with it, but a new straight through replacement cat section is only 15quid or so.

Click to expand...

sounds even nice like that too

and mine just went thru the mot with no cat. 96 300tdi
tho it did have one, its sat in me shed.

https://www.google.co.uk/search?red...=android-browser-suggest&qsubts=1403182734822

What about using a die to run down the threads of the welded bolts first?

bushwwacker said:

https://www.google.co.uk/search?red...=android-browser-suggest&qsubts=1403182734822

Click to expand...

try and buy one in the uk

Another method I was recommended was to cut a V shaped wedge by the edge of the bolt on the flange to help knock the bolt out, and then use a large washer with a new nut and bolt to attach the pipe.

Resolved in the end by heating it white hot with an acetylene torch and a couple of slaps with a big hammer. Out the bugger flew
In with brand new bolt and nut, now better than new

Big thanks to the guys at Maidenhead tyre exhausts Tyres & exhausts in Maidenhead, Slough and Marlow who did it in 5 minutes and didn't even charge me for it

My search for the split flange has also ended.