Looks like I don't have to make it myself - this is exactly what I was envisioning.

https://www.autozone.com/emission-control-and-exhaust/exhaust-pipe-adapter-connector/p/surebilt-2-1-4in-to-2-1-2in-laminated-split-flange/110783_0_0


those split couplers are rather flimsy, I bent several of ...

Think you want this forum - viewforum.php?f=26

The one you posted in is for 2001-2007.

Looks like I don't have to make it myself - this is exactly what I was envisioning.

https://www.autozone.com/emission-contr ... 110783_0_0

This seems more expensive than just getting a new down pipe. My FIL is a welder, maybe I can ask him.

New OE DP costs exorbitant money. The affordable ones are made of thin cheap steel and cheap ceramic converter, which your rear oxygen sensor will dislike. I have a good quality 3" downpipe ...

This seems too good to be true:

https://www.ebay.com/itm/135199870360?fits=Year%3A2007%7CEngine+-+Liter_Display%3A2.5L%7CTrim%3A2.5T+Wagon+4-Door%7CModel%3AXC70%7CMake%3AVolvo%7CSubmodel%3A2.5T%7CEngine%3A2.5L+2521CC+154Cu.+In.+l5+GAS+DOHC+Turbocharged&_skw=catalytic+converter&itmmeta ...

My problem is the holes aren't holes anymore. The bolts aren't stuck they're gone, so the holes are now effectively half holes. So a bolt won't stayed captive in the slot as its tightened. The holes have broken across the lines as on the attachment.

I was going to use stainless steel bolts for ...

Right now, eBay has a P2 S60 muffler for $150, genuine Volvo brand. I bought it this summer and can verify that it is genuine Volvo muffler.
Look under eBay seller "KTRXinc"...


I can get the muffler and resonator pipec at-back on parts geek for like 250, all in, or eBay for like 300. No problem ...

My problem is the holes aren't holes anymore. The bolts aren't stuck they're gone, so the holes are now effectively half holes. So a bolt won't stayed captive in the slot as its tightened. The holes have broken across the lines as on the attachment.

I was going to use stainless steel bolts for sure.

Hello.

I recently picked up a fairly nice 07 xc70. It pretty good shape but due to the Michigan winters it's in dire need of a new exhaust. I have found many stock options which is great, but then comes my problem.

Where the downpipes ends after the cat, the flange which mates to the remaining ...

Finally got around to testing this thing and it passed with flying colors.

HC - 0.0727
CO - 1.032

NOx even went down a little too.

I have to say it seems likely the o2 sensor was the culprit all along, although running some tehcron, 91 octane, and the MAF cleaner, along with the stage 0 probably ...