Exhaust hanger

[Blobcat]

After washing my car today I noticed that the exhaust was somewhat lower than normal at the back. I've been underneath it and the bracket that is welded to the back box has come off of part 50 on the attached http://www.detali.ru/cat/oem_mb2.asp?TP=1&F=210026&M=613%2E961&GA=722%2E626&CT=F&cat=66G&SID=49&SGR=285&SGN=04).
Where the hanger attaches to the back box has rusted through. The back box has no rust on it and neither has most of the hanger. It is only rusted where it used to connect to the box. I'm not that hopeful but do you think it is possible to weld it back on?
As the bracket is fairly think and the back box only pressed steel I think that the back box will hole as soon as the mig is applied.
Any thoughts?

 

[Sprint'n'Go]

Any fool can weld 5mm steel (look at me), the real skill is with the thinner stuff. I agree it could be tricky but don't give up. Is it possible to weld on a spreader plate to the box? so you are not trying to weld exactly where the original welds were and also where any corrosion has started. by doing this you should be working with fresh metal as you weld on the plate and if you use slightly thicker plate (2.5-3mm) it will give you a bit of meat to weld on the hanger. Obviously turn down the current while tacking on the plate and seam welding wont be necessary, then crank up the juice when you weld the hanger on. I dont know about you but my welding on thin plate can look a bit messy unless I am on a roll, but as the exhaust isn't structural I am sure there will be enough bite for what is required.

 

[Sprint'n'Go]

Where the hanger attaches to the back box has rusted through. The back box has no rust on it and neither has most of the hanger. It is only rusted where it used to connect to the box.

Any thoughts?

Sorry, just re-read your post. If the box is holed you will need to seam weld the plate.

 

[Blobcat]

Sorry, just re-read your post. If the box is holed you will need to seam weld the plate.

No holes in the box, once the remainder of the hanger is removed it will look like new. Not done any welding since replacing sills and floor in my old fiesta (now that steel was thin). The welder was my brothers and he lives 300 miles norht of me which is not that convienient for me. I will stop by my tyre and exhaust friend tomorrow and see what I can do. I really would like to weld it though as the system is perfect (normal MB quality) apart from this bracket comming off.

 

[Sprint'n'Go]

I will stop by my tyre and exhaust friend tomorrow and see what I can do. I really would like to weld it though as the system is perfect (normal MB quality) apart from this bracket comming off.

If your tame exhaust fitter has the right experience he may be able to weld it up with the acetylene torch as I believe it is much more suitable for patching up scabby old bits of tin plate?

 

[television]

Do what I did with my volvo rear hanger, use a adjustable clamp as used for Aerials (house tv) around the pipe or an exhaust clamp and adapt, see picture. And no my Volvo is not rusting away, I have just steamed it ready to Waxoil

 

[Sprint'n'Go]

Good fix Malcolm. I assume you welded the hanger to the clamp?

 

[television]

Good fix Malcolm. I assume you welded the hanger to the clamp?

Yes correct, I did. that has been like it for two years.

Malcolm

 

[Blobcat]

Do what I did with my volvo rear hanger, use a adjustable clamp as used for Aerials (house tv) around the pipe or an exhaust clamp and adapt, see picture. And no my Volvo is not rusting away, I have just steamed it ready to Waxoil

I would do Malcolm and I have Ae brackets available. The problem is that the bracket is welded to the top back corner of the box. The outlet pipes are too close together and too far away from the bracket mount to be able to use.

 

[malcolm E53 AMG]

Have yiou thought about creating a complete hanger from two lenghts of 50x3mm galvanised plate bent to the contour of the box. It will require bolting together at one end and the other can be clamped with a length of round bar threaded at one end for clamping and then shaped to suit the original hanger position.

 

[television]

How about those steel strips used in building that have holes all the way down the whole length , they come in a thin version, easy to bend and galvernised, just wrap it around the box and bolt it up.

malcolm

 

[Sprint'n'Go]

How about those steel strips used in building that have holes all the way down the whole length , they come in a thin version, easy to bend and galvernised, just wrap it around the box and bolt it up.

malcolm

Hang on fellas, Its starting to sound a bit like a bodge job. Where's the elegance? It should look like a merc underneath as well.

 

[Blobcat]

How about those steel strips used in building that have holes all the way down the whole length , they come in a thin version, easy to bend and galvernised, just wrap it around the box and bolt it up.

malcolm

There's a name for that stuff, but for the life of I cannot remember. I know I will wake up at some ungodly hour with the answer (Still sat outside on the patio at the moment, which for Wales is impressive)
If I cannot weld it I may drill a hole or two in the pressed seam and fashion a bracket from that to the original hanger. I know it's not original however it will be functional and strong, which is (or was) an MB trait that I admire.

 

[Blobcat]

Hang on fellas, Its starting to sound a bit like a bodge job. Where's the elegance? It should look like a merc underneath as well.

I bought an Avantgarde so I can get away with it :mrgreen:

 

[television]

Page 491 of screwfix they have builders band 20mm wide and 20 guage and full of holes.

You should be laying on your back looking under the car,instead of sitting on the patio.

malcolm

 

[Blobcat]

Page 491 of screwfix they have builders band 20mm wide and 20 guage and full of holes.

You should be laying on your back looking under the car,instead of sitting on the patio.

malcolm

I know what the problem is and would like to see if I can weld it before trying a different repair. Also I have spent way too many nights working till 3am getting a car back together ready for work the next morning to still be doing it now. Sat with a glass of wine watching the stars come out works for me now.

 

[Blobcat]

Sorted, the back box was thick enough to weld to. I will put some rust proofing on it tonight.

 

[Sprint'n'Go]

Sorted, the back box was thick enough to weld to. I will put some rust proofing on it tonight.

Is that MIG welding or Torch? Looking at the smoothness I would guess torch or a very good result otherwise.

That is the sort of workmanship I was hoping for, very elegant.

 

[Blobcat]

Is that MIG welding or Torch? Looking at the smoothness I would guess torch or a very good result otherwise.

That is the sort of workmanship I was hoping for, very elegant.

MIG by a local company I've used quite a few times (once to weld the handle back on the lid of my stainless steel kettle)

 

[clive williams]

MIG by a local company I've used quite a few times (once to weld the handle back on the lid of my stainless steel kettle)

Blobcat,

I hope they disconnected the electrics before they MIG welded it? Better still remove it off the car, which because of the weld quality I suspect they did. Nice job. Can I suggest spraying the weld with galvanising rich spray rather that other rust paints as it should last a bit longer as well as being abount the right colour/sheen?

Sprint, MIG or better TIG welding is much better on thin sheet as the shield gas cools the surrounding area preventing distortion. Additionally, it is possible to weld to rusty!!!??? metal as the new filler seems to bond to whatevers left of the clean metal in amonst the rust. Its enough to stitch thing together that are not too structural.

Clive

500E
E320CDIT210