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[YZ250]

Forgot to say, cosmetically speaking it's worth putting a 3.0 system on it as it will hang in all the same places. 

I've an almost new, complete cat back system from a 3.0l saloon. It was part of the job lot of bits that came with my project engine, and is of no use for my estate.

Webby, it's yours if you care to collect it.

Nick

Result. Nice one. 

Reference the flange bolts, they rust in but if you can get some movement from them, regardless of how little, you can gradually get them out by undoing until they resist, do them up slightly, undo a bit more and so on until the resistance is less. If you can get them out, they are re-usable. 

[Nick W]

Reference the flange bolts, they rust in but if you can get some movement from them, regardless of how little, you can gradually get them out by undoing until they resist, do them up slightly, undo a bit more and so on until the resistance is less. If you can get them out, they are re-usable. 

Getting them out is the key; even if the female threads are knackered, it's easy to run an 8.5mm drill bit through them, and swap to longer bolts. That's what is now on mine.

[martin42]

He learnt that trick yesterday 

[Webby the Bear]

Very true! It's amazing the tips you pick up from watching and listening to experts!

I have a tap n die set so drilling and making new holes wouldn't be a problem 

[hotel21]

In my opinion, not worth the hassle of retapping the holes. Simply drill through and use bolts instead of studs and nuts. That way when they seize/rust and you need to seperate then a hacksaw or cut off tool through the bolts then drift them out and job done. 

[Andy B]

In my opinion, not worth the hassle of retapping the holes. Simply drill through and use bolts instead of studs and nuts. That way when they seize/rust and you need to seperate then a hacksaw or cut off tool through the bolts then drift them out and job done. 

Or. ....... drill & tap the original holes & use stainless bolts from work 

I wonder what prat at Vauxhall decided to tap the part of the exhaust that you're like to keep rather than the bit that rusts and you throw away 

[kevinp58]

In my opinion, not worth the hassle of retapping the holes. Simply drill through and use bolts instead of studs and nuts. That way when they seize/rust and you need to seperate then a hacksaw or cut off tool through the bolts then drift them out and job done. 

Or. ....... drill & tap the original holes & use stainless bolts from work 

I wonder what prat at Vauxhall decided to tap the part of the exhaust that you're like to keep rather than the bit that rusts and you throw away 

Or just use Stainless nuts and bolts. 

[M Kerr]

   What a result this thread is!  I'll sleep well knowing that Utopia simply exists! Well done all! 

[Webby the Bear]

Yeah again a massive thanks to Nick (who i'll hopefully see Sunday) and massive thanks to Martin for previous help and help with fitting.

love OOF!!!!

ps, re the downpipe..... do you have to buy the cat with the down pipe as its all one pipe so to speak? noticed a big hol next to my o2 sensor

[kevinp58]

Yeah again a massive thanks to Nick (who i'll hopefully see Sunday) and massive thanks to Martin for previous help and help with fitting.

love OOF!!!!

ps, re the downpipe..... do you have to buy the cat with the down pipe as its all one pipe so to speak? noticed a big hol next to my o2 sensor

Yes I think they are all integral for the V6's