Paul-

    Getting ready for the return of my engine, and I need to get   the welding
    on my exhaust reworked.  Based on prior discussions here on  the  list, I
    know I must get the exhaust tubes rewelded to the inside of the
    mounting
    flange.  Before doing this, though, do I need to remove the   exterior
    welds, or are welds on both the inside & outside acceptable?

    Mark

    The heat damage is done already to the metal alloy. Can you
    shorten them about 3/8ths of an inch and just weld them on the
    inside?  Are they 321 SS and .065 thick?


I have no idea what the thickness or composition of the exhaust is --
perhaps Jerry could comment since he fabbed them for me.

As you can see in the pic, shortening the tubes is not in the cards -
the body of the exhaust VAM is already less than 1/4" from the   mounting
bolts.  Right now I have to install the nuts while the flange is only
partially mounted in order to get the nut to fit.  If I cut the tubes
down at all, it would be impossible to mount.

Also - I note in your 3D that you show the tube fully penetrating the
mounting flange.  I believe in my muffler that the tube is
surface-welded to the outside of the flange (no penetration at all)

Given all this, am I correct in assuming that the tubes must be  wholly
replaced & the flange bored wider for new tubes?

Mark

OK then fabricate some braces up to the engine block.
I'll do a 3D shortly. That will reduces the stress on the joints.

Order a couple of these things from McMaster Carr.
We will use the old intake manifold bolt holes.
-- 
Paul Lamar ...No rotor no motor.

Mark, examine your exhaust.  I believe I welded it i all around on
the inside of the flange and tacked  it  on the outside.  This is the
way I have done them for years.  Jerry

Mark, the inside weld was blended with a die grinder to better help
exhaust gas flow.  You have to look closely.
If in doubt measure the i.d. which is 1.875 for the two inch o.d.
pipe.   I.D. of the exhaust flange is 2.25 inches.   Your entire
system is 321 SS, .063 wall in case that comes up.  Are you piping
outside air through the cool tube?  That will keep the entire system
cooler and less prone to cracking (my theory)  Adding hangers is a
good idea.    Jerry



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