Hi all,
I installed a new Walker muffler and the connection between the muffler and tailpipe was a little tough to make because the tailpipe starts to bend and it means that there isn't a good section of flat pipe between both pipes to clamp.

I've attached several pictures.

I did have to grind the tailpipe around the edges to get it to fit inside the muffler outlet. It fit in there very tight.

As of now, the connection is not clamped or sealed other that the tailpipe being shoved into that outlet tight.

I have exhaust clamps (cheap u type), but I don't think they will really help here because the tailpipe section is curved at this location. That means a band clamp won't work either.

I am wondering about just leaving it...or how much would it cost to have a local muffler shop to weld it. I am hoping not too much.

thanks for any ideas,
Chris

 

Remove the rear sway bar and then drive to the local exhaust shop and have it welded for $5

 

The u bolt type of clamp will usually work because it will cause the pipe to smash a little to hold it in place, as long as you got the pipe in far enough.

 

I personally would not weld a stock exhaust system if you bought the right muffler for your XJ all should fit fine. The problem is welding new pieces to old, all new and setup high and tight at a shop then its fine I just did that to mine. For everything from the cat back tailpipe/muffler/exhaust/clamps/hangers installed including tax $94 out the door.

I want to keep my exhaust as high up as possible without any clearance issues as the stock system did so. Just make sure all the tailpipes are good before welding and in good shape, very little rust as they are cheap.

 

I'd bet a "U" clamp and a couple dabs of hi-temp copper rtv sealant in the small gaps would seal it up fine. Welds seem like they r a rust magnet.