Exhaust Components - Welded or Clamped?

[Ol' Bessie's Keeper]

Just wrapped up some engine noise in another post (timing chain got loose due to grendaded tensioner) and I now have some exhaust rattling. I'm assuming it may be the CAT heat shield, but I won't know until I get some time to remove the skid plate and really check over things. My CAT drive cycle monitor will not flip over, so it may also be the CAT itself rattling.

Regardless, in the chance that I may need to put in a new CAT and eventually muffler (it started spitting fiberglass), what is everyone's take on welding in versus clamps?

 

[hamhawk]

Just wrapped up some engine noise in another post (timing chain got loose due to grendaded tensioner) and I now have some exhaust rattling. I'm assuming it may be the CAT heat shield, but I won't know until I get some time to remove the skid plate and really check over things. My CAT drive cycle monitor will not flip over, so it may also be the CAT itself rattling.

Regardless, in the chance that I may need to put in a new CAT and eventually muffler (it started spitting fiberglass), what is everyone's take on welding in versus clamps?

Welding is definately the way to go. If you do use clamps, i suggest the band style ones. The u bolt/saddle style are garbage and usually crush the pipe in to the point where you cant get it back apart. Of course if you want to be really fancy you could use v bands.

 

[macleanflood]

In my 97 with a single cat next to the transfer case...I added a v band clamp just in front of the cat so I can drop my downpipe without removing the skid. After my cat is a regular slip and clamp that goes to my Hooker exhaust.

V bands don't leak. Everything else does.

-Mac

 

[Grant Lasson]

Mine was fully welded by the PO. I do not recommend. Replacing the exhaust after a rear main seal replacement was the most difficult part. When I replace it, I'll be using multiple v-band clamps.

 

[Ol' Bessie's Keeper]

Look forward to hearing any other input, good stuff so far. Of course, as I was heading over to Harbor Freight earlier to snag a stethoscope, the exhaust rattle fully stopped. I drove her like a bat out of hell, at all different RPMs to try to draw the rattle out, to no avail. So I'll start her up in the morning to see if she returns. I still snagged that stethoscope just in case.

 

[Sgt Jarhead]

Personally I am a fan of clamps just past where the mini cats come together and again before the exhaust goes to the skid plate. My opinion is based on the fact my Banks Turbo Kit sets it up to cut up the OEM exhaust for the install of the turbo.

Makes life a little easier if you have to drop the oil pan, mini cats, or exhaust for anything.

 

[BlueC]

I take it you're referring to custom exhaust systems. I prefer my exhaust to be modular/sectional similar to OEM, i.e. I can unbolt and reinstall a section without cutting and welding. My typical exhaust setup goes (1) head-to-cat/resonator/crossover, (2) center pipe and muffler, (3) over the axle and tail pipe. The individual sections are welded, then joined together by clamps. V-bands are the better clamp, but cost more.

If you're talking about simply replacing a factory setup, just use a premade kit that bolts together.

 

[GregBelleville]

In my 97 with a single cat next to the transfer case...I added a v band clamp just in front of the cat so I can drop my downpipe without removing the skid. After my cat is a regular slip and clamp that goes to my Hooker exhaust.

V bands don't leak. Everything else does.

-Mac

Hey Mac, for the v band clamp, is this what you're referring to?

I need to replace my muffler on my 99 from the cat back soon and may try to copy your setup.

PTNHZ Universal Stainless Steel 3.0" V Band Clamp For Turbo, Downpipes, Exhaust Systems(2.0"/2.5"/2.75"/3.0"/3.25"/3.5"/4.0") https://www.amazon.com/dp/B083DNFHR9?tag=wranglerorg-20

 

[macleanflood]

Yes, but I bought mine on Summit cause I've lost all faith in Amazon.

Not sure what size that is.

-Mac

 

[GregBelleville]

Yes, but I bought mine on Summit cause I've lost all faith in Amazon.

Not sure what size that is.

-Mac

Correct size would be 2.5"?

 

[Rickyd]

Correct size would be 2.5"?

That is just the band. you need the kit with parts that weld to the tubes

I used evil energy and have no complaints

 

[Gilaguy23]

Hey Mac, for the v band clamp, is this what you're referring to?

I need to replace my muffler on my 99 from the cat back soon and may try to copy your setup.

View attachment 493478

PTNHZ Universal Stainless Steel 3.0" V Band Clamp For Turbo, Downpipes, Exhaust Systems(2.0"/2.5"/2.75"/3.0"/3.25"/3.5"/4.0") https://www.amazon.com/dp/B083DNFHR9?tag=wranglerorg-20

Those bottom ones are T bolt clamps. I cant see using those instead of welding or the SS lap type clamps of the non lap bands. I have them on my F250 after the cat was stolen. It rides like a buckboard and they have yet to come loose.

 

[bluescapegoat]

My exhaust is all Evil Energy V-band clamps now. Makes pulling it out to do work, try out different components, etc, much easier.

Been using them for years, they're good quality.

 

[NskLJ]

Look forward to hearing any other input, good stuff so far. Of course, as I was heading over to Harbor Freight earlier to snag a stethoscope, the exhaust rattle fully stopped. I drove her like a bat out of hell, at all different RPMs to try to draw the rattle out, to no avail. So I'll start her up in the morning to see if she returns. I still snagged that stethoscope just in case.

My factory exhaust has a connection right behind the rear cat. I would do the same that way you can remove it if needed. There is nothing good about having to pull out a sawzall to service a vehicle.

 

[SSTJ]

I'm interested in these V-bands. Just looked up a few.

My exhaust system has two lap joints— one of each side of the catalytic converter. If I cut a notch into the outer/overlapping pipe, would a v-band work well around that? Or do I need to stick with something like this, which I currently have?

@macleanflood it sounds like maybe my setup is similar to yours.

 

[bluescapegoat]

I'm not exactly sure what you're asking in regard to the v-band clamps, maybe look up some videos on youtube to get an idea. Essentially you start with two pieces of pipe cut straight and weld the interlocking flanges to each pipe then the clamp holds them together.

In the event of eliminating a lap joint you'd cut the expanded section of pipe off so you're left with two pipe ends of the same diameter and weld the flanges on. Whether or not that gives you the proper length for what you're attempting to accomplish is something you'll need to figure out for your situation.

 

[mrblaine]

I'm interested in these V-bands. Just looked up a few.

My exhaust system has two lap joints— one of each side of the catalytic converter. If I cut a notch into the outer/overlapping pipe, would a v-band work well around that? Or do I need to stick with something like this, which I currently have?

@macleanflood it sounds like maybe my setup is similar to yours.

You have sorta been taken on a short trip down the garden path. While V bands are a good system, you can't use them without welding on the flanges for each side that the V band is used on. If you aren't going to weld, then something else will be needed.

For the record, the factory style conical semi-ball connection is a good system. I do lots of exhaust work and we rob those pieces and reuse them all the time but there again, we are welding in connections that can be taken apart easily for service. I am aware of V band, I have those parts, I just don't use them because I can generally rob enough parts off of the stock exhaust to get done and getting done is always good.

 

[SSTJ]

I'm not exactly sure what you're asking in regard to the v-band clamps, maybe look up some videos on youtube to get an idea. Essentially you start with two pieces of pipe cut straight and weld the interlocking flanges to each pipe then the clamp holds them together.

In the event of eliminating a lap joint you'd cut the expanded section of pipe off so you're left with two pipe ends of the same diameter and weld the flanges on. Whether or not that gives you the proper length for what you're attempting to accomplish is something you'll need to figure out for your situation.

View attachment 493637

Aha, thanks. I understand much better now. Appreciate it.

 

[SSTJ]

You have sorta been taken on a short trip down the garden path. While V bands are a good system, you can't use them without welding on the flanges for each side that the V band is used on. If you aren't going to weld, then something else will be needed.

For the record, the factory style conical semi-ball connection is a good system. I do lots of exhaust work and we rob those pieces and reuse them all the time but there again, we are welding in connections that can be taken apart easily for service. I am aware of V band, I have those parts, I just don't use them because I can generally rob enough parts off of the stock exhaust to get done and getting done is always good.

Got it, thank you.

Can you say more about (or point me toward) these factory style conical semi-ball connections? Is that what I'm familiar with where the down-pipe meets the exhaust manifold? I don't remember seeing any other kind of connection (other than a weld) for the rest of the length of my OEM exhaust.

 

[JMT]

I don't know if this is a good clamp for a cut exhaust or not, but I used it on @Irun's recommendation.

Walker 36530

https://www.amazon.com/dp/B01HQSWYXE?tag=wranglerorg-20