105 Exhaust pipe flange to 80 muffler flange

[voodu3]

I’ve finally got my inside the frame exhaust put together and it was going together great until I went to put the muffler section on. The flange on the 105 down pipe is 90*ish off from my 80’s muffler flange.

I’m looking for some help with what’s the best way to get them to mate up.
1. Try to cut/grind the muffler flange off at the weld turn it and weld it back up
2. Get a new flange and repair section for the muffler
3. Take it to exhaust shop and get them to make it work.
Any advice or suggestions would be appreciated.

 

[Marvelicious]

If you have to ask, I'd say option 3.

You can buy miscellaneous exhaust bends and cut/tack them together until you get something that fits like a glove if your weld/fab skills are up to it. It's thin material and not the easiest thing to work with. No slight intended, it's just one of those things where, if you have the skills to do it, you probably already know how. Then again, there's nothing like trying something new if you want to learn.

It's hard to judge how close it is from the pic, but I would probably leave the down pipe unmodified and cut and weld on the muffler side to make it bolt up. It doesn't look like they're far enough apart to justify another section and set of flanges in between.

 

[voodu3]

I think they will fit together as far as the length of the pipes. I’ll get a better picture. The bolt holes on the flanges are out of alignment. I’ve never messed with exhaust other than replacing parts. I wanted to make sure there wasn’t something I was missing on fixing the flange.

 

[Marvelicious]

I think they will fit together as far as the length of the pipes. I’ll get a better picture. The bolt holes on the flanges are out of alignment. I’ve never messed with exhaust other than replacing parts. I wanted to make sure there wasn’t something I was missing on fixing the flange.

Gotcha, so you just need to cut and turn the flange in the same overall location, just clocked 90 degrees? Oh yeah... if you aren't a super confident welder, I'd find some equally thin stuff to practice on - maybe even practice on some actual exhaust tube - but that's not a hard modification at all.

 

[voodu3]

Gotcha, so you just need to cut and turn the flange in the same overall location, just clocked 90 degrees? Oh yeah... if you aren't a super confident welder, I'd find some equally thin stuff to practice on - maybe even practice on some actual exhaust tube - but that's not a hard modification at all.

I appreciate your help. Would you try to reuse the existing flange or just get a new one? I’ve got all of my old exhaust pipes I can use to practice on.

 

[Marvelicious]

As long as you can get a nice, straight cut, I see no reason not to reuse.

 

[Fj80oregon]

You could always buy an exhaust coupler and skip the welding. Just cut a straight section rotate and bolt on the coupling.

https://a.co/d/jiFM0tG

 

[4runnin2]

Just scored a 105 series down pipe and plan on going inside the frame as well. Did you add in a cat? are you using a stock 80 series factory muffler back?

 

[bonestock]

I went with a universal summit cat and a m3 bmw muffler the shop I went to had available. Sounds legit. Almost like it’s turbo.