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Date:         Fri, 23 Apr 2004 11:19:46 -0400
Reply-To:     Matt Sutton <msutts@EARTHLINK.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Matt Sutton <msutts@EARTHLINK.NET>
Subject:      exhaust leak fixed (?)- inspection passed!
Content-type: text/plain; charset="US-ASCII"

Hi Folks, Just to wrap up the story:

At the last writing, I had a cracked exhaust header where the pipe meets the head at the #1 cylinder. Got all kinds of feedback for a temporary fix, tried a few with mixed results. JB weld burned of into a powder pretty quick, didn't try the hi-temp silicone ( the stuff I found was only rated 100 deg. higher than the JB Weld). Ended up with a product called Muffler Weld. It doesn't burn off, but isn't very strong, and I had to do a couple applications to build up the joint. That too eventually failed, of course right during the high RPM section of the dyno test; too much movement at that joint I'd guess. I heard the leak open up, and resigned myself to a failed test, but miraculously it it passed with these crazy numbers: HC CO NOx LIMIT 1.60 40.0 2.50 RESULTS 0.05 0.69 0.11

Don't really know how to interpret the #'s, but am glad to have gotten through. Having a nearly new cat. converter probably saved my butt, but running by the book timing and idle could've helped. Now at least I've bought time to save up for some new headers.

Thanks for all your advice.

Matt Sutton 88 GL


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