Help with Exhaust

[Aches n Pains]

Need help with a set of exhausts for the new project. PO had cut the end out of the original pipes. I have the set shown below in my inventory. Problem is getting out the inserts from a previous life somewhere.

Both the headers and the pipes are 1.5" ID. Therefore, I will need to use a 1.5" OD insert to join the pipes.

Problem is that I can't get the old insert out. Tried PB blaster for weeks. Tried lots of heat. Enlarged the slots in the pipes. Even welded a piece across the insert and beat on it with a rubber mallet till it broke off.

Any suggestions would be hugely appreciated.

Aches n Pains

[motoman]

No idea.........but a decent set of Jardines with the cross-over............

[justme1100]

Chip away at it

My suggestion would be to use a dremel tool with a metal cutting disk to the inside, just don't cut all the way through, until it comes loose or you cut enough away to insert new connection. Good luck.

[ManagerMike]

Assuming you are trying to remove the inserts from the pipes in the picture, that is a basic skill learned early on for anyone trained in automotive exhaust repair. Using a cutting torch, one cuts the insert
from the outer pipe so that it comes out in two pieces. I still call them "muffler bearings" as they resemble rod or main bearings in a standard cage engine.
The trouble with using the torch method in your situation is the discoloration of the chrome that would result. Therefore I suggest a reciprocating saw with an appropriate blade to cut the insert through lenghtwise at two opposing locations, then remove the two resulting 'muffler bearings'.
Do you follow?

[fredintoon]

- - - Problem is that I can't get the old insert out. Tried PB blaster for weeks. Tried lots of heat. Enlarged the slots in the pipes. Even welded a piece across the insert and beat on it with a rubber mallet till it broke off. - - -
Any suggestions would be hugely appreciated.

Hi Doug,
try this:- weld a 1/2" nut to a fat washer.
Grind the washer OD so it fits the end of the insert and weld it in place.
Thread your slide hammer into the nut and go at it!
But FIRST CAREFULLY CHECK that the PO didn't plug weld that insert in there.

[Aches n Pains]

Good suggestions. Will try the reciprocating saw first and then the welded job. Also a good tip to be sure there isn't a weld inside the pipe.

Thanks,

Doug