2G How To (Easily) Install Your 3" CatBack Exhaust.

[Drop Top Road Trip]

So you may have read on another thread that I ran into a problem upon my initial effort to install my new 3' SRS stainless catback exhaust system. Following the advice I received in that thread I gave it another shot. I took lots of pics and did a detailed post on my 2g Eclipse Spyder blog: Drop Top Road Trip. Check it out if you are having any issues installing your exhaust or just like to read about this kind of stuff.

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[Drop Top Road Trip]

::sigh:: So....I went to finish up the exhaust install and this happened. The Cat to Exhaust flange gasket is Way too big. I guess this gasket is for an install to a Cat delete pipe. But then, today I go to find a gasket at NAPA Auto Parts and they tell me that the outlet of the stock Cat is not the 2" that mine measures. Well, I think I got a gasket that will work (as the one supplied and pictured below clearly will not work). We'll see soon.

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[honda_burner]

I haven't purchased one in a long time, but one time when I did, it came with an adapter to take size down. The gaskets were chincy paper too if I recall. They didn't hold up.

 

[Drop Top Road Trip]

As it turns out, the supplied Cat to Exhaust Pipe flange gasket is too big for the exhaust pipe as well. Supplied part fail. No problem. NAPA Auto Parts to the rescue.

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[Drop Top Road Trip]

Well crap. I FINALLY got the entire exhaust on and tightened up...only to find the down pipe rusted through. ::sigh::

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[1g Cam]

You have another downpipe?

 

[Drop Top Road Trip]

You have another downpipe?

Not yet. Looked around on c-list. There are a couple of part-out cars there but neither got back to me when I inquired about a downpipe.

I think I might call Road Race Engineering and order their Short Downpipe and High Flow Cat. Just all new stainless steel then front to back. This exhaust is probably gonna outlive the car by about 80 years.

 

[97 eclenger]

exhaust shop can weld it or like i did for a temporary fix, use exhaust putty. it hardens up like a rock. not the chevy kind of rock. thats just weak. but like cement tough.

 

[Drop Top Road Trip]

exhaust shop can weld it or like i did for a temporary fix, use exhaust putty. it hardens up like a rock. not the chevy kind of rock. thats just weak. but like cement tough.

Hmmm...I kinda looked at that stuff online. Take a look at that RUSTY crack...not much metal left there. You think it'd last any time at all? Thanks for the suggestion, either way!

 

[2gmitsueclipse]

exhaust shop can weld it or like i did for a temporary fix, use exhaust putty. it hardens up like a rock. not the chevy kind of rock. thats just weak. but like cement tough.

There needs to be metal to weld to. That piped appears to be pretty roached and replacement would be advised. The cement also will not work.

OP: I would also suggest inspecting the condition of your motor mounts for excessive movement. Excessive movement can cause premature wear on the flex-section of the new down pipe among other issues.

 

[1g Cam]

At least you have an excuse for a new downpipe, match that new catback.

 

[Drop Top Road Trip]

There needs to be metal to weld to. That piped appears to be pretty roached and replacement would be advised. The cement also will not work.

I had my doubts, there's not much left of that piping. Note also that the heat shield is gone. That exhaust must have been the original. Surprisingly, other than the surface rust (which needs to be addressed before it goes deep) there doesn't appear to be a rust problem under here, and none on those front strut towers.

OP: I would also suggest inspecting the condition of your motor mounts for excessive movement. Excessive movement can cause premature wear on the flex-section of the new down pipe among other issues.

Will do, I mean...it can't hurt to check them out even though the DP is probably toast just due to general rust through. The original cat back had a big hole in it where an exhaust hanger brace broke off, taking with it a 1"x2" piece of the piping that it was welded to...due to rust through.

Thanks for the advice.

 

[Drop Top Road Trip]

At least you have an excuse for a new downpipe, match that new catback.

Exactly! Love having a Legit excuse! Sad that I'm not just enjoying the car though.

 

[1g Cam]

I'll be honest I have an eBay TBE, I'm gonna get a thermal in the future since I'm making more money now, I bought a downpipe on there for $70 not the best way to go but some situations call for it.

 

[Drop Top Road Trip]

I'll be honest I have an eBay TBE, I'm gonna get a thermal in the future since I'm making more money now, I bought a downpipe on there for $70 not the best way to go but some situations call for it.

I'm somewhat limited in my options because I want to keep my cat or get a high flow cat. Looks like it's RRE, stock or (I think) the $400 Tanabe. Anybody know of any other bolt on DPs that keep the catalytic converter?

 

[chrysler kid]

I'm somewhat limited in my options because I want to keep my cat or get a high flow cat. Looks like it's RRE, stock or (I think) the $400 Tanabe. Anybody know of any other bolt on DPs that keep the catalytic converter?

My car has to pass the sniffer test here in Texas, mitsubishis obd2 shows not ready and it tosses it back to the sniffer test. Best option, pick up another oem downpipe to keep as a spare when inspection time comes around

You could just have an exhaust shop make you a 2.5 down pipe, they really don't have much to them, but I'm in the same situation for now. Need another 5 years to be exempt

 

[Drop Top Road Trip]

You could just have an exhaust shop make you a 2.5 down pipe, they really don't have much to them, but I'm in the same situation for now. Need another 5 years to be exempt

I guess that having a shop build a mild steel 2.5 would be fine. Won't be as sexy as a purdy lil stainless steel piece, but who am I trying to impress? I do prefer to be more hands on and get all anxious when handing off any of my vehicles to a shop. Nobody ever cares about our cars like we do.

Thanks for the reply and advice.

 

[chrysler kid]

I guess that having a shop build a mild steel 2.5 would be fine. Won't be as sexy as a purdy lil stainless steel piece, but who am I trying to impress? I do prefer to be more hands on and get all anxious when handing off any of my vehicles to a shop. Nobody ever cares about our cars like we do.

Thanks for the reply and advice.

I edited my post, pick up another stock one used for cheap to keep as a back up and just run those one piece units on flea bay. When the inspection comes around just toss the old oem downpipe and cat back on

 

[1g Cam]

We don't have emissions in Nebraska so I'm one of the lucky ones

 

[chrysler kid]

We don't have emissions in Nebraska so I'm one of the lucky ones

Your car is also 25 years old and exempt from emissions testing too

 

[1g Cam]

Good ol 1g. Gotta love that test pipe

 

[PlanZero]

You have two options, unless you really want to shell out extra money for a short pipe.
1) Get a DP for $80 off ebay, eliminate the cat, put a $5 O2 sensor spacer so you don't get a CEL. Depending on your states emission procedures, you can get away with no cat if they don't do a visual inspection.
2) get same ebay DP and a high flow cat, cut it short and weld the DP, cat, and resonator pipe on the catback into one long piece. I did this years ago and worked out great. Meineke charged me $40 at the time to weld it and I slapped it on in the parking lot.
After trying to install a cat back the first time on a 15-25 year old car I will never do it again. Just replace the whole exhaust. I have an apexi ws2 with a Megan DP and magnaflow hi flow cat on my AWD, and a straight eBay turbo back on my fwd. Both are great.