exhaust fiberglass and rust - what to replace?

[enotslim]

The short pipe on the rear muffler is slotted as shown in the fcp image of the Starla muffler. It seems this will be expanded to be larger than 2.5 cm if the center muffler pipe slides into it. Does that mean the pipe from the rear muffler slides into the pipe from the center muffler instead? That would remain 2.5 inch OD. Might this require some sort of space filler, like aluminum tape or exhaust cement, to fully seal?

[XC70Rider]

Does that mean the pipe from the rear muffler slides into the pipe from the center muffler instead?

NO. As I stated earlier the long center muffler pipe slides into the short rear muffler pipe.The long center muffler pipe is narrower than 2.5" so it easily slides into the rear muffler.

Might this require some sort of space filler, like aluminum tape or exhaust cement, to fully seal?

If the clamp fits well and you fully tighten it then it will only require muffler cement or sealant.

Your rear muffler has already been tampered with. That clamp isn't how they factory install. They weld the two muffler together at the factory. The reason for the slots on the new rear muffler is for tack welding. After it is tack welded you hang the exhaust low enough to weld the outer edge of the rear muffler pipe onto the center muffler pipe. That's what I will be doing with my Bosal catback.

Remove the rear muffler so you can get definite answers on what parts will be needed to mount the new muffler.

[enotslim]

Success ... I guess. Swapping the new for the old muffler was incredibly easy (one of the easiest repairs I've done) once I hacksawed my way through the existing pipe ... which was a major pia because I had to do the entire second half by hand, using a hacksaw, with diminishing clearance. Toward the end the blade only moved 0.5-1 inch per stroke. Painful and took several hours. The first half took a few minutes with a Sawzall and good metal blade.

However, I discovered a few things. One, XC70Rider's description was perfect.

NO. As I stated earlier the long center muffler pipe slides into the short rear muffler pipe.The long center muffler pipe is narrower than 2.5" so it easily slides into the rear muffler.

Might this require some sort of space filler, like aluminum tape or exhaust cement, to fully seal?

If the clamp fits well and you fully tighten it then it will only require muffler cement or sealant.

Your rear muffler has already been tampered with. That clamp isn't how they factory install. They weld the two muffler together at the factory. The reason for the slots on the new rear muffler is for tack welding. After it is tack welded you hang the exhaust low enough to weld the outer edge of the rear muffler pipe onto the center muffler pipe. That's what I will be doing with my Bosal catback.

Remove the rear muffler so you can get definite answers on what parts will be needed to mount the new muffler.
[/quote]

However, the rear muffler pipe had been shortened so an adapter was required to extend the 2.5in width the full length of the clamp. Plus the clamp was shimmed. Pieces are in the attached photo. The shiny clamp is new, obviously.

The old muffler was wearing a blanket. See photo. Significance? Is this necessary? Is it asbestos?

Anyway, the new muffler is now installed exactly as XC70Rider described. Minor adjustments for positioning but it works.

Thank you for your help!