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Muffler pipe flaring - pipes won't mate 900

posted by  Horatio on  Sat Feb 14 15:10 CST 2009
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last visit: Wed Aug 20 22:11 CST 2014
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My 1995 940 needed a new muffler so I got a Walker ($65 lifetime) and it needs to mate on the overpipe which was installed by Craven Tires (prior owner) 3 years ago so, it is also aftermarket. I know the quality is not up to Volvo standards but it seems too late to turn back now. It looks like the clamp on the overpipe cause that pipe to flare out so it is too big to mate. That's my theory. Consequently I got a flaring tool to make my new pipe flare out so I could fit it over the old too-big pipe. I had partial success but the pipes mate only about one inch, if that. Any ideas? Is there a way to make the overpipe smaller so it will fit into my new muffler? Should I cut slits in it and try to squeeze it or would that just make it oblong and leaky? I am even wondering if both pipes are so out-of- specs that that really can't be made to fit right. I've put on a few mufflers over the years and this is the first time I've seen where the two pipes appear to be the same diameter and therefore mating is nigh impossible.






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