This dreary tale started when I needed a front header pipe for my 90 240. I was surprised to find that Autozone could get a Bosal pipe to me for $85. After reading some good things about Bosal on the Brickboard, I ordered one.

The problems started when I yanked the old header only to find that it had a spin flange while the Bosal used a welded flange connection. Because Autozone had only the one style in their listings and because they could sell me a new cat for only $95, I decided to also change the cat.

The next problem was that the welds of the manifold flange on the front pipe had to be relieved a bit so that the nuts would cinch up. Then I had to fabricate another front pipe bracket because the attachment on the Bosal missed the mark. Figuring I was now good to go, I proceeded to install the Bosal parts to find that the cat pipe hung a little low. The real show stopper occurred when I went to slip the rear half of the exhaust system onto the cat pipe. The new head pipe/cat were about 2 inches shy of full engagement with less than an 1 inch of the cat pipe slipping into the middle muffler inlet.

My questions:

1/ Did I get the one bad head pipe or cat in the Bosal boxcar, or do they all fit so poorly?

2/ Is there a decent fitting (and affordable) alternative to the platinum standard of original Volvo exhaust parts?

3/ If you are a bondsman, will you sent me your business card so that I have it in my wallet whenever I go back to Autozone?

Rich