Like having to get a new exhaust for the Discovery. It’s easy to get the intermediate and end pipes, as a standard unit fits, but the down pipe has to be specially made to connect to the 2.8 litre engines manifold. A couple of years of off roading had taken its toll on the down pipe, while some spectacularly poor reversing had destroyed the nothing for it the rear silencer pipe. There was nothing for it.
Without the silencer, the Tdi isn’t actually that loud in normal use, just a bit throaty. its only when you floor it that the noise picks up. New pipes were cut and bent using mandrels and the ends were flared using a swaging machine, allowing one pipe to fit over its neighbor. Where the pipe work was too intricate to join two with rear swags joints, they were welded.
A hole was cut through the exhaust to exit and the sharp edging strip, though you probably have to fix something a bit more permanent at some point. With everything in place it was a case of popping down the road and giving it a shakedown to make sure that everything was tight and the exhaust well fixed. The first run showed that the extra leverage of the side exiting pipe was causing a few headaches and the pipe was causing few headaches and the pips needed to be super tight to stop it from rotating. If we had smeared exhaust putty along the joins before it was connected, it would probably have stopped the rotation. As it was a quick tighten soon had the pipe held firmly in place and effectively silencing the engine.
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