Tiny hole in exhaust - how to seal up?

[Welly]

The Volvo's eggsauce system has disgraced itself after 11 years and is showing a tiny hole in the tubing with tell-tale black soot coming out. You can just about hear a slight leak when close up so it's not too bad....yet.

I was thinking of getting some high-temperature mastic and gobbing over the little hole with a generous blob? thinking the mastic would remain flexible and just kinda stay put?

[PeterN]

Unfortunately once it has perforated that generally indicates that the whole area around it is thin and likely to break out somewhere else. I have welded up pipes where the end has rusted off only to find a little while later that it breaks off further down.

For that reason I would think that your idea is probably the best, at least it will make it last a bit longer.

Peter

[Doggy]

Put some gunge on it & put a hose clip or similar over it.

A proper 'Engineered' bodge should look like it's meant to be there.

[trufflehunt]

Just remembered a post I made a couple of years ago. I did get a new system, months later.
But the repair I did was still going strong.

Anyway here's the post....

" The exhaust middle section on my D9 HDI has been blown for some time.
On the pipe where it curves towards the rear box.

I've kept on 'fixing' it with exhaust bandage, gun gum, and also had a
go with that Holts sleeve thing that you fasten round the pipe.

I would have fitted a new section by now, just the weather has been
too wet for scrabbling, and knuckle grazing, around underneath.

None of the fixes lasted long, a few days usually.

Anyway, I tried another tack. Got some aluminium adhesive
tape, and wrapped some of that round the pipe. Then some
high-temperature repair tape.., the kind that cures and bonds with itself.

That was a week ago. Checked underneath this afternoon. Looks as
good as new. .... "

---------------------------------------------

The brand name of the high-temp tape was Quik Tape, but pretty sure it comes under various names.
one of these things originally developed by/for the US military.

[Welly]

Cheers all, I think a 'dirty' fix is the way to go having had a very brief sniff around at replacement exhaust prices

[highlander]

I had a cat-back stainless system designed, built, and fitted (including VAT) for £360 on my Coupe, with limited lifetime warranty.

I went for it because it worked out cheaper than buying a complete mild steel exhaust system from Peugeot, which would have been the third such system that had been fitted to my car in its 9 year life (it's now nearly 14 years old). Its previous owner had put a complete new genuine exhaust on just two years previously, and it was leaking through the rust by the time I took it for its first MOT under my care. And I will never need to replace it again, because the new system will not rust away to nothing.

It just makes sense to do it.

Since I got mine done, I've read plenty of accounts of other Coupe owners getting their cat-back stainless steel systems designed and fitted for considerably less (around the £200 mark). Everything is more expensive in and around Aberdeen. Tony Banks is a name I've seen bandied about a lot as being both cheap and good, but I have no idea where they are in relation to you.

[Doggy]

Gordon Banks was in Welly's neck of the woods, any relation?

[Welly]

So I've been thinking and first needed to know how hot the rear silencer and tubing get. This is non-406 related so it's a 2.5 petrol turbo, after a decent run and sort of trying to get the exhaust 'hot' as soon as I arrived home I left it running and grabbed my Aldi pointy thermometer:



You can't see but that's pointing at the tubing entering the rear box. So now I've ordered some 300 deg C flexible mastic to splodge over the small hole/crack in layers hoping for a flexible repair*

More fascinating* updates to follow.....

[PeterN]

That seems quite hot, although I only know diesels which generally run a lot cooler, hope its a success.

Peter

[Welly]

I've splodged over the hole (well more crack really) with some high-temp industrial mastic and it has worked. What might have caused this was ruined rubber hangers so off I went to get new rubberz fitted to stop it wanging around as much.

The tubing feels 'soft' to the point where a firm squeeze would probably end it all, it's been on 12 years.

For entertainment I asked the exhaust man to cost up a replacement system for me, he went off for ages, made phone calls etc, came back with a saddened face; "we can't source an exhaust for this car no-one makes them" it's a Main Dealer only part

Needless to say I haven't enquired yet, but might do just for a laugh.......

[steve_earwig]

Arse Life just wouldn't be the same without the occasional wallet implosion hanging over us

I'm sure any exhaust place worth their mild steel could make you a system, that's all they seem to do here anyway. I guess, once you've picked yourself up off the floor, you should get a quote for a stainless system, it'd probably be cheaper and maybe even a selling point to boot . "yeah, it's got a full cat-back Highlander mate."

[Doggy]

(Egg sauce, I meanz).

[dirtydirtydiesel]

Tony Banks is in Leeds, his custom built exhuasts start at £400.00 or there's
Mij exhuasts in Walsall, Birmingham theirs start at £295.00 & have a very good reputation

[dirtydirtydiesel]

Walters,
What flavour is the vulva, Mij exhuasts have one on the bay of e for a S60 pezzil for £ 294.99
Hope this helps DDD.

[Welly]

It's an S40 T5, caused quite a stir in the eggsauce shop as they'd never been asked to look at the piping before although said it was extremely similar to the Focus ST (I know this but pretended to be surprised, it's the same apart from my tail pipes point downwards).

I have seen a Ferrita system from that Sweden, imported by Kalmar Union tuney-people for £435.00 a Cat-Back system, that doesn't seem too bad. Tempting extra was the Downpipe and Sports Cat as I know the downpipe on mine is restrictive and mega gains can be had here but that piece is £545.00 alone

I can see the conversation with her-indoors already........ although I think even I'd baulk at the total cost there.

Be nice if the sporty stainless system is less money than a standard MS system good thing is with it being a Turbot engine it won't be too loud on the road.