Is this exhaust system joint about to fail ?

[rollin_home]

I was looking closely at the exhaust system on my Volvo and the joint looks bad and about to fail.
What do you think based on these pictures, can or should anything be done to replace the rusted bolts or should it be left alone ?

Thanks !

(PS , I specifically didn’t state the year and model because this is a generic issue and applies to all)

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[Blacklab467]

You can buy the gasket in between those pieces, replace it and cover it with never seize. Replace the bolts with stainless steel M12 by 30mm. The flange is usually ok and pretty robust and thick.

[scot850]

Looking at the last 2 pictures it looks like someone may have either been hammering on the flange, but more likely they have welded the 2 sides together. That may make the joint harder to fix if that is the case. Otherwise BlackLab247's suggestions I am in agreement with too.

The joint is more likely to fail by the bolts being so corroded.

Neil.

[BlackBart]

I’ve always used copper hardware, the muffler shop guys nod and say thanks when they see it.

[jonesg]

its not like the timing belt where failure destroys the engine.

I got another 5 yrs when mine started leaking, using assorted rescue clamps, exhaust cement and high temp sealant.

[abscate]

Bear River Converters in LA make cool flanges and adapters that you can band clamp in when needed, if you don’t weld. I would run that for the next 27.5 months of the life that is left because..

I’m cheap
An asteroid might hit the planet and kill us all anyway
A random polar bear may roamLong Zisland and eat me and I don’t want my money in a new exhaust of that happens

[rollin_home]

Thanks for all the suggestions!
It appears that the rust had somehow welded everything together. It’s hard to believe that’s stainless steel. Maybe I’ll try and separate and remove then replace the center bolt and see how that goes . One new bolt will at least keep it together . This corner bolts and flange look almost totally consumed by rust .

Wow, that Bear River Converter company has an amazing catalog. Thanks for that . There surely has to be a solution in there for my exhaust system:

https://www.bearriverconverters.com/Ima ... atalog.pdf

[jonesg]

It can turn into quite the project.
I horsed mine around so much I ruined the flex pipe above the cat, then I had to pull the top section and re-weld a new flex pipe in.
That required making a jig to hold the downpipe and cat in position for welding.

The flange joint ears for the bolts were rusted away so I resorted to split flange clamp to draw them together.
Once you break the seal you're all in, the flange faces should be refaced , I used a small belt sander, the rear pipe can be pulled back enough to get the sander in there.

If you use a band clamp it requires grinding away the ears on both sides, I used a $10 split clamp instead.

https://www.amazon.com/SHINTONES-Univer ... r=8-3&th=1

[jonesg]

You can buy the gasket in between those pieces, replace it and cover it with never seize. Replace the bolts with stainless steel M12 by 30mm. The flange is usually ok and pretty robust and thick.

look at the second photo down, the ear is already rotted off.