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Discussion Starter #1
I'm now getting a raspy sound from the exhaust on start up, especially when cold. Investigation now shows that there is a split on the large end of the cone section immediately before the catalytic converter. Looking at it, its like the original wel hasn't penetrated the sections of metal properly, and where its split is perfect smooth, even thickness metal.

My thoughts are to drop the exhaust ( oh yay ! :roll: ) and then try and weld the seam back together with my el-cheapo mig welder.

Is that something that can be done without too much fuss ? Is the exhaust standard steel, or is it stainless steel?
 

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Re: Can the exhaust cat box be diy welded ?

Yeah go for it. There's absolutley no problems with welding up an exhaust box. I've done it loads of times. As long as it isn't rusted out.
Try sticking a magnet to it to see if it's stainless.

I've had several boxes mainly cats which have cracked at the seams. Main dealer always wants to replace them. I just weld them up.
 

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Re: Can the exhaust cat box be diy welded ?

great - thanks for that. my big fear was being able to undo the down pipe / manifold nuts, but they came off fine, so i shouldn't have too many problems with getting the rest off.
 

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Re: Can the exhaust cat box be diy welded ?

The cat/exhaust is stainless steel, I tig welded mine as its more controlable than mig. Mine was split in the same place around and through the weld. As the whole system is in one piece, I cut and sleeved it on the straight section behind the cat to save dropping the complete system.
Stewart.
 

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Re: Can the exhaust cat box be diy welded ?

Well, job done ...

ripped out the whole system ... its bleedin heavy, and bleedin huge:



its quite apparent that someone has patched it in the past ... and its given up ...



so wire brushed it all back and the gap is really visible...





and considering how crap I am at welding, i managed to put a relatively neat weld along it ( neat by my standards ! ). It was magnetic, so i don't know if its SS or not, but it welded fine.





Refit was a PITA, very heavy and not much play to align things, but got there in the end. Finally an engine reset of the errors ( the engine could sense the hole as it was putting the engine light on ... the hole must have been causing the O2 sensors to give funny readings ) and now its running as sweet as a nut. Quiet and smooth.

Very pleased with the result and how much money its saved !
 

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Re: Can the exhaust cat box be diy welded ?

Nice e-pix, Thanks for the info!
this sounds like it's related to the extended exhaust warranty that we're getting letters about on this side of the pond.
 

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Discussion Starter #7
Re: Can the exhaust cat box be diy welded ?

i'd agree. I was thinking the same looking through some of the other posts recently talking about it.

I was a perfect split. I think the welding machine was out of line a bit. The other welds on the other parts had obviously more penetration nad looking much better.
 

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Re: Can the exhaust cat box be diy welded ?

I had mine welded up a couple of times over the past 3 years think its about due again as getting the familiar blow again!

Wonder if its worth approaching LR UK as LR NA are now covering them then again i can anticipate their response :lol:
 

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Re: Can the exhaust cat box be diy welded ?

I just got a message from Land Rover Canada indicating that due to a problem with the weld in the catalytic converter the warranty on this was being extended to 2011 or about 190 k km.
I guess lrna must have something similar.
 

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Re: Can the exhaust cat box be diy welded ?

Monty said:
Wonder if its worth approaching LR UK as LR NA are now covering them then again i can anticipate their response :lol:
I'd think it's worth a try, and likely to be succesful. It's part of the emission control, and considering that the U.S., as much as I love my homeland, is not respected as the leader in environmental senstivity, I wouldn't think we would be at the forefront of the concern. That said, I'd expect nations that are more environmentally concerned than the U.S. to not bat an eye at the thought of doing the environmetally "right thing". Bad emissions control system = more harmful gases released. Nobody wants that.
So I'd think you have a good shot if you refer to the LRNA reference they could probably find what you're talking about.
 

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Re: Can the exhaust cat box be diy welded ?

Norval said:
I just got a message from Land Rover Canada indicating that due to a problem with the weld in the catalytic converter the warranty on this was being extended to 2011 or about 190 k km.
I guess lrna must have something similar.
Norval

Can you pls scan that and join a pdf to your reply . We may have to use it in old Europe as we did not receive anything like that .
Thanks in advance .

Jaybear
 

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Re: Can the exhaust cat box be diy welded ?

WAIT! LRNA just extended the warranty on some cars for the Cat to 11 years/120,000mi so you might be covered....check with LRNA
 

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Re: Can the exhaust cat box be diy welded ?

Sorry Fisha, I should have said. If it's magnetic it's mild steel and can be welded mig tig or arc. If it isn't magnetic it's stainless and slightly more specialised.
 

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Re: Can the exhaust cat box be diy welded ?

jaybear said:
Norval said:
I just got a message from Land Rover Canada indicating that due to a problem with the weld in the catalytic converter the warranty on this was being extended to 2011 or about 190 k km.
I guess lrna must have something similar.
Norval

Can you pls scan that and join a pdf to your reply . We may have to use it in old Europe as we did not receive anything like that .
Thanks in advance .

Jaybear
Here is the letter for North America: viewtopic.php?f=2&t=32764
 

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Just to clarify, the system IS Stainless Steel, there are many different grades of stainless, both magnetic and non-magnetic.
Stewart.
 

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Most exhaust systems are 409 stainless steel which is Magnetic... it's got mostly chromium in it... with very little nickel which is what is the big property in 304 SS
 
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