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Yeah, the bolts were too short, so I reused the thinner ss bolts I had on the old cat. It would, probably, have been better to get longer bolts of the same grade and gauge, but I'd have to take down the header pipe to drill out the holes in the flange, and I'm not in the mood for that at this point. I don't see how I could drill out the holes with the pipe in place, but I might try to enlarge them a bit in situ with a rat tail file.
On to another matter. Since I had to wait for the converter to arrive, I decided to replace the other exhaust components, except the header pipe, with pieces I had already on hand - purchased last winter. After I had everything installed and started up the engine to check for leaks, I noticed condensation leaking from the first muffler were the upward bent rear connecter pipe goes into the muffler body. After spending the appropriate time in my moaning chair, I took everything aft of the cat down again to weld the leak closed. It took three passes with the Mig to get a proper seal.
As I tested the weld with water, I noticed that the crimped joint in the top of the muffler also leaked. I know, at that point I should have called Tasca and returned the thing to them for replacement, but (a) it was 8 months ago I bought it, and (B) I want to get on with the job and get the car on the road by this weekend. So I'm going to try to seal that top joint with goop. My choice is between JB Weld and VersaChem's Exhaust Joint and Crack Sealer. Which, in your opinion, is the best of these lousy options, or do you have a better idea?
Thanks,
Bob S.
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