I was just at the dealer to have a broken connecting pipe replaced, and as predicted they stated that I need a new exaust from the manifold back. They quoted me about a thousand bucks (with taxes) for this. I am thinking I could get a nice stainless sport exaust system made for much less. Has anyone done this? Any recommendations for a high flow cat that would fit? My car has the O2 sensor in the cat. Are there any problems with moving it up nearer the manifold?

On my '84 240 DL, the exhaust system from the manifold back hasn't deteriorated a bit, except for the cat which has been replaced due to cracks and failure of the element. I assumed that the pipes and mufflers must be stainless, because I can't find a hint of rust anywhere after 300k miles of use, except for some bolts. If they're not stainless, they must have some magic galvanizing on them, or something equivalent.

The stock catalytic converter seemed prone to cracking at the weld where the pipe joins the housing. I went through two OEM cats that way, the second one was picked up used for $50. Last time I replaced the cat I bought a cheapo NAPA $100 unit, plain steel pipes. Fits fine, passed emissions with flying colors, so far so good.

Mike

Where did you find a place to buy a used cat converter?
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Volvo 240 Links

Yup my cat is cracked. I've already had it welded once. It holds for awhile. You either have stainless pipes or you must live in Texas! My year and a half old system has pinholes in the downpipe, a blown out seam in the first muffler, broken connecting pipe (from rust), plus the cracked cat. I am not in a very gook mood today as a result.

$1000 US dollars for exhaust???? (*@$#&(%*&%$^ Sounds like they are trying to rip you a new one!

A stainless system in, say 2.25 inch, would be nice, and would probably be less $$. Then you'll never have to worry about that crap again!

Or you could get mail order parts and install yourself, it wouldn't be too difficult. That'd be the cheapest.

Greg

No 1000 bucks Canadian. $480 for the cat, 380 for the rest of the pipes and mufflers, and sales tax. We pay 15% sales tax up here. You guys south of the border are lucky that way. But that was what I was thinking. 2.25 pipes, a high flow cat, and one muffler. Possibly a turbo muffler? I live on the ocean in a smow belt and I go through steel exaust pipes about every year and a half, so I want to try stainless.
What type of exaust to you have on your V8 Volvo Greg?

It's a dual system with 2.5" stainless pipes. They are not mandrel bent, that would have been way more $. Would either need a shop with real expensive equipment, or have em weld together a system from bent parts.

There are 2 2.5" cats, and a balance pipe. (connects the 2 systems) Both mufflers sit where the rear muffler was. So one pipe runs down the left side, goes into the muffler, and exits on the right. Other pipe does the opposite.

I haven't had it long enough to comment on it's durability, but from what people tell me, it should last the life of the car. I just have to keep an eye on the rubber hangers. The mufflers are not stainless.

It's got a nice sound, not too loud, and it absolutely snarls when you hit the gas! At idle, most people don't notice it, especially if they're sitting in a Lexus, or other isolation pod.

Greg

Doesn't Volvo charge like ~$800 for the new cat? Maybe that's why it's so costly. I just installed the $96 Starla system this morning and it runs and sounds great. It took a few hours, but not a bad deal. Even with an aftermarket kit you're looking at just a few hundred instead of a thousand. The IPD sport exhaust looks exactely like mine except they removed the front muffler and charge $50 more for it.
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'86 245 DL Volvo Blue/ Blue Vinyl M46

Yeah I am considering that, but I kind of want to put a high flow system on. The turbo system is actually larger than the stock system