Manifold Flex Pipe Exhaust leak looking for Ideas please?

Post by **plumsmooth** » 15 Nov 2016, 08:15

I just failed inspection and I have noticed my Wagon getting louder and louder over the last year gradually.

In fact the other day right before my inspection it got even louder

Now I smell Exhaust and i know where it is coming from!

I would really prefer to come up with a master-patch-plan for Flex Pipe...

And put off replacing the Exhaust Manifold until further notice...

It is obviously not worth welding if you have to take the Manifold off to do it.

Maybe some Titanium Header Tape and three hose clamps and stainless zips ties.

Maybe some high temperature rated GOOP

Anyone please?

I noticed someone used to make (i think someone still does) a weldable replacement flex pipe for this situation!

But can't seem to find one in U.S>

Post by **plumsmooth** » 15 Nov 2016, 08:30

Also, I am wondering if there is any reason why a flex pipe and some muffler clamps wouldn't do the job?

Post by **theWIFES_S70** » 15 Nov 2016, 14:52

plumsmooth wrote:Also, I am wondering if there is any reason why a flex pipe and some muffler clamps wouldn't do the job?

I think you can do this...

This is the official DIY flex pipe repair
https://www.matthewsvolvosite.com/forums ... hp?t=39723

I'm headed to a local muffler shop Tuesday next week to see what they say and how much it'll cost to do everything from the flex pipe on back. I'm guessing (hoping no more than $300). But really thinking about just getting a stainless steel header off eBay and rolling the dice...

Try it out and see what happens. I love our P80, but this flex pipe/manifold all-in-one is a real pain...

Post by **plumsmooth** » 15 Nov 2016, 15:10

Thanks I have read the thread... Seems there are lots of ideas left unexplored, like High Temperature Silicone, Titanium Tape with Stainless Zip ties or Hose Clamps? Also Being that the Flex Pipe can be accessed from the top and bottom maybe it can be done without removing the Manifold.
Because let's face it that defeats the purpose. I can order a complete Manifold Kit for 160 including all gaskets and hardware...

IT wouldn't make sense to have it welded by taking off the Manifold?

Therefore there must be some other ideas?

To me the main issue is sizing the differential between the inside or outside of the manifold port and the Catalytic Pipe Feed?

Am I wrong? Because for that matter why couldn't one just get some flex pipe and clamp it down on two sides? I mean we are taking about connecting two pieces of pipe here. How difficult should it be?

Post by **theWIFES_S70** » 15 Nov 2016, 15:38

I think you can DIY weld with the manifold in place, if you take off the exhaust manifold heat shield.

I like how you're thinking!

I could see two larger diameter flex pipes cut down the middle, layered over one another, wrapped in titanium tape and held together by a dozen or so stainless steel zip ties working...

Would love to see a picture of that...

Post by **plumsmooth** » 15 Nov 2016, 16:03

I think you can DIY weld with the manifold in place, if you take off the exhaust manifold heat shield.

Yeah it seems you can do half from the top and half from the bottom (pun intended)...

As far as the Titanium Header Tape, one could almost pull it off from the top (no lift -- pun Not intended)...

I wonder if WE could combine High Temp Silicone Gasket Goop with the Titanium Tape and Securing Hardware and get 5 years plus?

The point I am making is if one's lower manifold's connections to engine is good, why replace the whole thing for one measly rusted piece or holes in flex pipe that should have been Stainless Too begin with!

Post by **theWIFES_S70** » 15 Nov 2016, 17:00

I agree totally. I'm in worse shape though: the cat and muffler are pretty shot. And when I rev past 3K rpms the engine sounds really bad, like there's something preventing the car from breathing. I just need to spend the (hopefully) $300 now and get to work on it sometime in the Spring when I have more time... I know, it's spending money twice. But I just don't have the two-three-four days to dedicate to it and to all the unavoidable hiccups that might (most likely) arise. Please post pictures!

Post by **plumsmooth** » 15 Nov 2016, 17:21

preventing the car from breathing

Has the Volvo had a PCV replacement yet?

Post by **tryingbe** » 15 Nov 2016, 17:28

Find a replacement downpipe and cut weld the cat on.

Anything else is going to fail inspection and emission.

Post by **cn90** » 15 Nov 2016, 19:21

plumsmooth,

Of course you can buy dealer Exhaust Manifold but it costs a lot of money.
Search forum for OBX etc.

I wrote the following DIY for my 1998 V70 a few years ago...

DIY: 1998 Volvo V70 Exhaust Manifold Replacement
https://www.matthewsvolvosite.com/forums ... hp?t=40032