Exhaust system sort-of upgrade SUCCESS

[BennyM]

Over the weekend, Triton540i and I replaced the exhaust system (everything from the headers back, except the cats) with a much cleaner used system I bought for $75. Neither of us had ever done exhaust work before, so it took a lot of time. But, all in all I feel it went pretty smoothly.

It helped a lot to take the rear bumper off, which is really easy.

I also lucked out by having a neighbor who could weld the newer pipes to my catalytic converters.

The biggest tip I can give anyone else trying to do this on their own is: don't try to install the whole system as one piece. Instead, install the front pipes and cats first, then bolt on the mufflers. It's impossible to line everything up otherwise.

Also, the rubber donuts at the very back are a bitch. No way around it.

I've got lots of pics to share. Thanks to all those who gave me advice here.

http://i63.photobucket.com/albums/h132/bennyboym/DSC00014.jpg

http://i63.photobucket.com/albums/h132/bennyboym/DSC00015.jpg

Liquid Wrench, torch flame, air-tools, and a grinder were all necessary to separate the cats from the resonator.
http://i63.photobucket.com/albums/h132/bennyboym/DSC00016.jpg

http://i63.photobucket.com/albums/h132/bennyboym/DSC00025.jpg

http://i63.photobucket.com/albums/h132/bennyboym/DSC00027-1.jpg

http://i63.photobucket.com/albums/h132/bennyboym/DSC00024-1.jpg

http://i63.photobucket.com/albums/h132/bennyboym/DSC00034.jpg

Piles of rust everywhere.
http://i63.photobucket.com/albums/h132/bennyboym/DSC00029-1.jpg

http://i63.photobucket.com/albums/h132/bennyboym/DSC00036.jpg

Cutting the pipes off the cats.
http://i63.photobucket.com/albums/h132/bennyboym/DSC00038.jpg

All bolted up before it's under the car. Oops.
http://i63.photobucket.com/albums/h132/bennyboym/DSC00041.jpg

Man, I hate these rubber donuts.
http://i63.photobucket.com/albums/h132/bennyboym/DSC00046.jpg

In the end the car is much quieter. The only problem I wasn't able to solve was how to fasten the rear heat shield. All the fasteners are rusted to the bottom of the car and the nuts are just balls of rust so there's not good way to even replace them. Any ideas on an alternate way to fasten the shield to the car? I'm going to try zip ties next.


BennyM

[BigKriss]

good work., i wish I could weld

[Kibokojoe]

What were the "new" used exhaust components from?

[BennyM]

A '92 525i that was parted out because the dealership couldn't resolve some bizarre title issue. So the car was in pretty good shape. I didn't even have to save the old O2 sensor.



What were the "new" used exhaust components from?

[stx133]

s/s cable ties are available (though a pest to source) to fasten things on or near hot exhaust components.

[genphreak]

Nice work, that is the right way to handle it. Good luck with the heat shields, those SS ties sound like the way to go. Plastic will probably melt/crack off, strong as they are.

Looking at those pics, you could start a website 'isitshotorwhat' :D