Exhaust Leak Repair

[glachica]

Hello Friends, I discovered a hole in a pipe leading to the resonator on my 1992 500E. As seen in the attached photo, it looks like corrosion and rust surround the leak in the pipe. What is the best way to repair this?

 

[gerryvz]

To me, that looks a little too extensive for welding the hole shut. I think you're going to have to have a competent exhaust shop drop the exhaust, cut that out, and weld in a new section. Shouldn't be too big of a deal -- perhaps a couple hundred dollars at the most to get it fixed. The main thing is to get a competent shop that knows what they are doing.

 

[glachica]

To me, that looks a little too extensive for welding the hole shut. I think you're going to have to have a competent exhaust shop drop the exhaust, cut that out, and weld in a new section. Shouldn't be too big of a deal -- perhaps a couple hundred dollars at the most to get it fixed. The main thing is to get a competent shop that knows what they are doing.

Many thanks Gerry. I really appreciate your advice.

 

[gsxr]

Gerry is correct, the location of the hole would make it difficult to repair "on the car". It should be removed for proper welding / repair. That part is NLA so you definitely want to save it if possible. It appear to be in very good condition other than the hole.

This item can be difficult to separate from the catalyst pipe (also NLA). The fittings are unique and not available aftermarket. Make sure the shop is careful to separate them without damage. It's not easy.

 

[glachica]

Gerry is correct, the location of the hole would make it difficult to repair "on the car". It should be removed for proper welding / repair. That part is NLA so you definitely want to save it if possible. It appear to be in very good condition other than the hole.

This item can be difficult to separate from the catalyst pipe (also NLA). The fittings are unique and not available aftermarket. Make sure the shop is careful to separate them without damage. It's not easy.

View attachment 123806

Thank you gsxr. I appreciate it.

 

[LWB250]

For what it's worth, I had a similar situation with a seam that separated on one of the pre-cats on Mrs. Dan's 1997 SL500 a couple years ago. I have a very good exhaust shop that does custom work and good welding who dropped the pipe off the header, welded the seam and put everything back together for $150. It wasn't cheap, mind you, but it was money well spent.

If you don't already have one, look for a shop that does custom exhausts. They typically have the people and resources to do this sort of thing properly.

Dan

 

[glachica]

For what it's worth, I had a similar situation with a seam that separated on one of the pre-cats on Mrs. Dan's 1997 SL500 a couple years ago. I have a very good exhaust shop that does custom work and good welding who dropped the pipe off the header, welded the seam and put everything back together for $150. It wasn't cheap, mind you, but it was money well spent.

If you don't already have one, look for a shop that does custom exhausts. They typically have the people and resources to do this sort of thing properly.

Dan

Thank you Dan.