Go Back   986 Forum - The Community for Porsche Boxster & Cayman Owners > Porsche Boxster & Cayman Forums > DIY Project Guides

Post Reply
 
LinkBack Thread Tools Display Modes
Old 09-25-2010, 01:19 PM   #1
Registered User
 
Join Date: Aug 2007
Location: Virginia
Posts: 244
I put on the secondary bypass pipe last spring. Had the same issue with the welded on nuts on the header outlets. Do you have an air compressor and air tools? For me, an air powered cutoff wheel did quick work of the mild steel nut.
__________________
-- John
'00 Boxster S
'86 911 Carrera Coupe (Sold)
Lucky is offline   Reply With Quote
Old 09-25-2010, 01:30 PM   #2
Registered User
 
Join Date: Aug 2007
Location: Virginia
Posts: 244
Forgot to answer your fitment question. You shouldn't have any issues. Just reassemble everything, but leave the fasteners loose. Tighten the muffler mount bolts, then the bolts/nuts on the header flanges. Finally tighten the two sets of clamps once you are happy with muffler tip alignment and clearance between the bypass pipes and the underbody tray.
__________________
-- John
'00 Boxster S
'86 911 Carrera Coupe (Sold)
Lucky is offline   Reply With Quote
Old 09-25-2010, 02:53 PM   #3
Registered User
 
jaykay's Avatar
 
Join Date: Sep 2009
Location: toronto
Posts: 2,668
exhaust clamp to Sec cats

Thanks Lucky......no I dont have the cut off tool and air compressor! Looks like I need tools!

Another hang up right now is the large clamp from the muffler to the secondary cat. I can only move it a few centimetres. Any good tricks to spreading it besides a torch?

I suppose removing the bumper will allow me to swing at it but I am try to avoid that
jaykay is offline   Reply With Quote
Old 09-25-2010, 03:08 PM   #4
Registered User
 
Join Date: Aug 2007
Location: Virginia
Posts: 244
Quote:
Originally Posted by jaykay
Thanks Lucky......no I dont have the cut off tool and air compressor! Looks like I need tools!

Another hang up right now is the large clamp from the muffler to the secondary cat. I can only move it a few centimetres. Any good tricks to spreading it besides a torch?

I suppose removing the bumper will allow me to swing at it but I am try to avoid that
Try wedging your largest flathead screwdriver into the clamp and then twist it if you need to spread it more. To ease reassembly, spread those clamps as much as you can once you have everything apart.
__________________
-- John
'00 Boxster S
'86 911 Carrera Coupe (Sold)
Lucky is offline   Reply With Quote
Old 09-25-2010, 03:35 PM   #5
Registered User
 
jaykay's Avatar
 
Join Date: Sep 2009
Location: toronto
Posts: 2,668
Yes I wished that worked...........I had a pry bar in there!
jaykay is offline   Reply With Quote
Old 09-27-2010, 02:06 PM   #6
Registered User
 
jaykay's Avatar
 
Join Date: Sep 2009
Location: toronto
Posts: 2,668
Anybody have to torch the big clamps at the end of secondary cats to get them to side??? Mine wont budge without some major hammering (using a flat head on the sleeve it self)!
jaykay is offline   Reply With Quote
Post Reply



Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On




All times are GMT -8. The time now is 10:48 PM.


Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2025, vBulletin Solutions, Inc.
Content Relevant URLs by vBSEO 3.6.0
Copyright 2025 Pelican Parts, LLC - Posts may be archived for display on the Pelican Parts Website -    DMCA Registered Agent Contact Page