mathslope

I live in the northeast aka rust central and my 2005 es330 240K miles is taking a beating. My exhaust pipe is cracked at the flex pipe, hanger near the cat, and flange joint between the cat pipe and muffler. Of course the flex pipe is welding onto the cat, my goal is to drop the exhaust, cut out the flex pipe, and weld on a new one.

Question: What size replacement flex pipe do I need, and where do you recommend I go?
Flex pipe: 2.5" OD at each end; 7" weld to weld; 5" of ribbed flex pipe.

For the hanger, I'm going needle the rust off and lay a few beads of weld to secure it.

Not sure what to do with the rear flange joint, was thinking about cutting out the original joint and welding in a new one, something like the picture below. But is this a doughnut flange? My current set up doesn't have spring bolts so it seems like a normal flange?

Going to replace all the bolts and gaskets of course. Wish a replacement stainless steel model didn't cost more than the car is worth.

Arsenii

Hello,

Some pictures of the exhaust setup in your car would be helpful.

May be mistaken, but I don't think your car ever came with an actual Flex Pipe, it should use bolts with springs, here you can find a diagram of the setup, it could be that you are not the first one there. Either way, unless you have a lift and a good welder set for stainless, I really doubt you will have a good time with it, may be a lot easier to buy the pipe as an assembly, either aftermarket or used, may end up being cheaper in the long run as well for not having to re-do everything if it leaks again.

Hope this helps and best of luck!