Finished the broken header downpipe replacement today, after replacing the bent passenger-side control arm yesterday. *Much* better access to torque the rear bushing with the downpipe removed.

On the new Bosal downpipe, I found the flange-to-pipe fillet weld on the exhaust manifold end encroached on the flat surface needed to seat two of the three (new, flange-type) copper nuts. I inserted a regular split-ring lock washer to raise the nut above the weld. Should there be any problem with this?

On the old Volvo pipe, there must be a bevel weld on the face of the flange, because there is no weld (and plenty of room for the nuts) on the back of the flange.
--
Jim (90 244DL 170K miles)