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gtx 95 weld upper exhaust pipe?

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rbbengineer

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the purple pipe right off the exhaust manifold has two round looking plugs welded there rusted out with pin holes can i fix them can weld steel so is this the pipe alm or steel i know i hear the plug is alum but what is the pipe? anyone know the best fix
 
your best fix would be, if you dont buy one, is to JB-Weld it. Welding itself wont work, since the pipe is made from pop metal...
 
the pipe is aluminum. welding works. don't bother though. gouge out the hole and sand it clean. JB weld with a little bit of fiberglass cloth strands pushed into the hole to stop the JB from running in.
 
Just repaired the same issue. JB weld is good stuff but not for this repair (past a weekend fix). Take the pipe off and open your local yellow pages to the welders section. Call ahead and find someone who will weld alum via a tig machine. This is not hard to find but make sure it is a tig shop!
Have them grind off and replace all four plugs on your pipe with 1/8 inch T-6 alum only (due to the heat on the pipe)! The most you will pay is $100 and you will never worry about it again.

To save a few bucks use your grinder to remove the old welds/plates only and prep the pipe with a common file (to make sure it is flat for the new welds) for your local welder. This way you only pay for min time (saves about $40). To save even more money if you have the time, cut the round replacement plates of 1/8 T-6 stock to 1 1/2 inches diam. prior to showing up at the welder. In mostcases you can get it done while you wait!!!! I spent three hours total removing the pipe, grinding the old ones off, cutting the new plates and driving to the welder for the job. It cost me $40 plus the time and gas money, as reference.

If you drop it off at your local dealer they will charge you $150-$200 for the same fix. Plus the labor to remove and replace the pipe (add $150 more). Not a bad price if you dont have the time....

Be sure and use a new gasket and the high temp sealent (for the slip joint) when reinstalling the pipe. Good luck...You will be back on the water the same day!
 
aluminum huh..didnt think that..:ack:. Thought all these darn purple pipes were same casting material
For now, couldn't he tap hloe, and plug w/stain screw w/ jb weld for now. (maybe bit extreme, but...?)
 
Cast Alum. for the pipe itself. The plates are T-6 regular alum. This is why the need for a tig welder. This is not a big deal to repair, just time and a little calling around. Be sure and don't grind any more than the old welds off and then clean up the surface with a file only. This will expose the internal casting that you need to leave intact. If the internal casting is broken have this welded also but I have never seen one bad no worries. Your dealer can help repair this also, no need to buy a used one because it may have the same problem right away!

If this is all too much for you, take a look here.

http://cgi.ebay.com/ebaymotors/ws/e...viewitem=&item=180282718132&_trksid=p3907.m32

This is a guy on e-bay that does the service for you via the mail.:seeya:

Good luck!
 
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i used crap epoxy on my 93 GTI in the salt without even removing the pipe. forgot about the repair until i took pipe off 4 years later cause the engine finally died. this repair will last.
 
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