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The problem is getting the welder up into odd places to do full 360* welds. If I could remove the exhaust in sections and take it out of the truck, like it was originally built, this wouldn't be a question.

If I involve your dad in this, it'll turn into an all weekend project. I'll figure something out.

I swear this store must have gotten a new inspector. My truck had more problems than the Montero does, and the same place passed it in like, 15 minutes.

For what it's worth, neither Kansas nor Michigan have any of this nonsense.

Find another shop, or get crafty with JB weld.

(another shop)

It's a $12 inspection. I tried calling Goodyear today, but they only do by appointment.

I bet the small shops on Wornall would pass him...

Short video this evening starting her up. Little hard to start at first as it’s sat a whole day on in my driveway with the fuel pressure bleeding off. That’s also on 5 year old gas. Hopefully this helps you see how different ours are upon startup.

https://youtu.be/zi9YyGxcoBM

Also looks like my tach and fuel gage don’t work. Guess I’m on the hunt for a new cluster at least.

The new ignition switch came last night. It seems to start fine now. I'm not going to swap the starter just yet.

I said fuck it and welded the joint where the Lancer muffler connects to the existing pipe. It looks like ass because I was laying on my side without even jacking the truck up, but it's sealed. Now it sounds like there's a smaller leak closer to the engine. I'll bet it's the manifolds

Good, one more thing fixed. Hope you dont have a cracked manifold like I do.

Hmm. I was thinking of trying to pressurize the system, but this looks a hell of a lot easier.

https://www.instructables.com/id/Find-a ... our-hands/

[quote=""Jeff V.""]Hmm. I was thinking of trying to pressurize the system, but this looks a hell of a lot easier.

https://www.instructables.com/id/Find-a ... our-hands/[/quote]

I would be afraid pressure testing would cause more issues seeing as exhaust isn’t really pressurized.

I like the vacuum though. Also if you had a thermal gun an exhaust leak would show up easily.


Coop

Umm, an exhaust is pressurized. It's not a lot, but that's why it leaks. Hot gas wants to expand, and the muffler also adds to the pressure.

[quote=""Jeff V.""]Umm, an exhaust is pressurized. It's not a lot, but that's why it leaks. Hot gas wants to expand, and the muffler also adds to the pressure.[/quote]

It’s very....very little. It more finds the path of least resistance. It doesn’t take much to seal or more direct exhaust.


Coop

Pressure testing it to 2-3 PSI would be fine. But the shop vac is easier to set up.

With the vacuum if you had anything that would smoke, you could easily see any air.


Coop

I've got an old Halloween smoke machine buried somewhere in the basement

Even those sticks that you burn to put off a smell. I forget what they are called but they are like a buck. They would work.


Coop

Incense. I don't think that would produce nearly enough smoke for what I need.

[quote=""Jeff V.""]Incense. I don't think that would produce nearly enough smoke for what I need.[/quote]

I’m talking crawling under it and following the exhaust. You would have to hold it next to the exhaust but it would work. Smoke machine would be 10x’s better though.

Another option is sea foam, will make the truck smoke like a son of a bitch and you will see any coming out where it’s not suppose to.

Coop

3-5 psi is perfectly safe. When a cat gets plugged you'll see 30+psi before the cat.

Chrysler has a tsb for a specific O2 code that specifically states to pressurize the exhaust to find a leak. IIRC it states not to exceed 3psi

I've got a fine grained regulator that I use for pressure testing intakes. Now that I think about it, I might have a rubber adapter that'll work just as well on an exhaust pipe.

I'll try it tomorrow. Got plans with Vira tonight.

I clicked no links, but the old trick I always did was to just cover the exhaust outlet while it is running. If the exhaust is sealed well it should actually stall the engine. If it is not sealed you should be able to find your leaks.