I have a 93 4.0 Cherokee. My cat passed inspection by less than a hair a few months ago so to improve efficiency/help the environment I am going to replace it. While I'm down there I'm going to put on a new 40 series muffler while I'm at it and probably a better looking tip, too. None of the piping is rusted through so I am going to just reuse all that I can.

Anyway, with these new components is there anything wrong with just clamping everything to save money? I could cut slits to allow expansion and slide the piping in to each other, then clamp down.

I ask this based solely on a cost to benefit consideration. I can get clamps on eBay or Amazon for right around two dollars a pop. And my rear hanger has rusted off so I'd have to replace that for just under 10 dollars. The other options is of course to take it to a shop for welding but that is going to cost more. Is it worth it? I don't consider the Jeep a performance vehicle lol. I can even use gaskets with the clamps probably still for less than getting it all welded.

Please give any input and if I'm over-estimating the cost of welding also let me know, thanks.

 

Get it welded so it is air tight, but i'm sure i'll get flamed for getting it done right.

 

Band clamps.

 

Yeah I expected people to make the air tight / no leak argument. Do you have any reasons as to why that would be so important? Especially if I use a gasket to seal the link between the piping and the cat.