First Post - Warped Downpipe
 

Hello All -

I am new to this forum - I have a '92 1.6L with one of the early FM turbo kits with the IHI turbo and Link (MKII) engine management.

Recently, I had to have a crack in my downpipe welded and in doing so ended up with a slightly warped downpipe. It's not a major problem, but not the distortion in the pipe is just enough to cause the exhaust to contact the power plant frame just behind the cat.

Any suggestions for "adjusting" the shape/angle of the downpipe? I thought about heating it up and trying to bend it, but have concerns that may lead to more cracking.

Thanks!

I'd adjust the point in the pipe that makes contact with a big hammer. That'll keep your volume and alignment. Just won't be pretty - fortunately nobody will see it.

bend the hanger on the midpipe a little.

stick a crowbar in ther and pry it over. Also consider using a band clamp on an exhaust hanger to pull it away

I have thought about trying to bend it without heating it up but was concerned that I'd crack the turbo outlet housing. I guess the other option would be to take the downpipe off (ugh) and try to bend it off the car.

The problem with bending it off the car is you don't know what kind of change you're making without reinstalling it. And you're right - using mounting points to leverage a bend does stress them. Whether or not your concern is justified is another question - but denting the pipe avoids those issues at the price of aesthetics and flow.

The worst part of the problem is that the pipe is touching the PPF at the flange behind the cat and rear section of the pipe. Unfortunately, I really can't deform it there to keep it from touching. It doesn't sound like there are any good fixes without taking the pipe off to adjust.

Oh well....as I told my CFO (aka my wife), I guess its time to pull the IHI turbo off the car and install a new Garrett turbo and downpipe. Sounds like the only REAL solution to the problem.

post up some pics please

can't you just pull it and take a grinder to the flange?

Yes - that would probably help, but I suspect that I'd have to take off more of the flange than I'd really want to.

I'm thinking now of trying to use pair of wedges on either side of the pipe to brace the upper section while prying on the lower section of the downpipe. I'm hoping that the wedges will limit the torque applied to the turbo flange and housing.

Try loosening up the fasteners holding the dnpipe to the turbo. Pull the pipe away from the interference and retighten.

Corky - thanks for the suggestion. I will give that a try also.

Do you still have the jig for making the downpipe for the old FM/IHI kit?

Thanks!

Red, I think so. Will look as soon as I can remember it long enough to get from my desk to the old jig pile.