How And Why To Install Exhaust Flexible Properly

More often than not, very little thought or intention goes into replacing an exhaust flexible. All that this does is create more opportunities to replace exhaust flexible. The process usually looks like this: Cut off the clamps; Cut a slit down each end, trying not to cut through the pipe inside; remove with a pry bar and hammer. Re-installing is little more than measuring the approximate length; Cutting it with a chop saw or grinder; Squeezing the new piece into place and throwing on some clamps. Then it leaks.

The problems with this are that the exhaust flexible is, believe it or not, directional. And they’re liable to unravel despite the clamps on each end. The following is how to, step-by-step, prepare and install an exhaust flexible. Including a few tips to make it even easier.

Choosing exhaust piping

As with any Piece of exhaust, the material is an important choice to make. Colour and look have nothing to do with it. One is not more expensive because it’s pretty. Stainless steel is more expensive because it resists corrosion better, and because it can handle up to around 1500°F. Galvanized can only handle 600°F. With today’s aftertreatment systems, it’s no longer wise to buy galvanized. Temperatures in the DPF can reach over 1000°F.

How to prepare the exhaust flexible

1- Tack weld one spot on either side of where you plan to cut. You want to do this so that the flexible

If you don’t have a welder, then you can reinforce the interior with a piece of pipe and put a punch mark.

2- Now the Flexible can be cut. You can use a bandsaw, chop saw or grinder with a cutting disc.

3- Trim the ends with shears, or a grinder. You can use a file or grinder to make sure there aren’t any burrs that can damage something else in your exhaust system.

How to install flexible

Installing is as simple as you make it. Typically, the reason you have a flexible is because there are two fixed parts that may not always line up, therefore the need for flex. The first thing you want to do is compress the flexible as much as possible. Then, if practical, you may choose to loosen one of the ‘fixed’ components to create more room to install the flexible.

Once the flexible is compressed and one fixed end is loosened, the installation will be easy. This is especially important because a flexible is usually placed in an incredibly impractical position. When stretching out the flexible once both ends are in place, the flexible should be halfway between compressed and stretched out. This is what gives the most room for flexibility between fixed parts.

Conclusion

It doesn’t take much talent to make a better installation. And it doesn’t cost much more to get a higher grade material. With today’s aftertreatment systems it’s more important than ever to splurge on the stainless.

Also, some concentrated effort at the beginning of the job will make the installation last longer, and be easier.

Drive safe,

Kevin Gauthier