BDR header to side pipe slip fit repair.

[madmaxx]

The earlier BDR's had issues with the slip fit from headers to side pipes. Two ways to resolve, weld flanges $$$$$, use a tail pipe expander. I have a Lylse tail pipe expander I used once to permanently resolve my issue. I paid $80.00, I do not need it anymore. This is not the cheap harbor freight one that breaks in half or the freebe rental at autozone. It has ball bearings and you can easily expand your pipes with a crescent wrench. You do not need to take the headers off the car but you do have to remove the sidepipes. This is a "professional" tailpipe expander.

It took me approximately 1 hour per side, I bought a small piece of tailpipe section which matched the side pipe ID. I slide the tailpipe section over the header inserted expander and turned the wrech until fit was snug between header and tail pipe, installed side pipe and was done.

Found it in my garage in the original packaging. If you want it $40.00 plus shipping.

Thanks

[uncltodd]

What's it gonna cost me to have you hand-carry the tool to SE Oklahoma, and do the fix on Build #139? I can't do this kinda stuff any more, even if I knew what I was doing.

Nice motel, gourmet meals prepared by UT, whatever it takes.

Hey, I'm the guy that packed the exhaust joint full of steel wool with a mallet and punch and secured it with a hose clamp to stop the noise! Total failure, that's a flex joint.

UT

[madmaxx]

You have to have a neighbor, or friend in his 20's that can do this for you. Removing the side pipes is a joke, you unbolt the bolt by the door take off the springs and it will fall on the ground, you do not want to scratch the car. Then get a piece of exhaust pipe from Autozone the same size as the ID of the side pipe (in fact the size is posted on this forum) insert tool in end of header and crank on expander nut until pipe is expanded. I used a crescent wrench and had no problem. This thing is meaty with bearings etc, it is not like the cheap ones and will expand the pipe with very little effort. If I lived close I would do it for free. It is thearuputic to lay there on a piece of cardboard and do it, she thinks you are busting your but when you are actually sleeping on the garage floor LOL. The expander is actually designed for an impact wrench but it expanded the pipes so eaisly that the impact was to fast.