Trickle Posted November 14, 2015 Share Posted November 14, 2015 So my exhaust seems to be blowing on my 2.9 Cayman, i'm pretty sure it's from the drivers side but not entirely sure where. Is it likely to be a join somewhere rather than a hole in the pipe itself? I've read it could be a gasket gone, common problem..? Link to comment Share on other sites More sharing options...
Founder Beanoir™ Posted November 14, 2015 Founder Share Posted November 14, 2015 Very common. Most likely the join, the bolts rust (3 on each side) and then the gasket fails. The parts are cheap to buy but often the old studs need drilling out which is not an easy job. I had both sides of my old Cayman done and it was less than £200 labour included etc. 1 Link to comment Share on other sites More sharing options...
Trickle Posted November 15, 2015 Author Share Posted November 15, 2015 I was kind of hoping to give it a go myself. Did they have to drill your seized bolts out do you know? Link to comment Share on other sites More sharing options...
Founder Beanoir™ Posted November 16, 2015 Founder Share Posted November 16, 2015 On 15 November 2015 at 17:10:11, Trickle said: I was kind of hoping to give it a go myself. Did they have to drill your seized bolts out do you know? I believe so yes, it's a bit of a pain of a job to be honest, I was quite happy to pay for the job to be done on mine. The annoying thing is the replacement bolts form Porsche are still just a poor quality steel that will rust away again 5 years time. Link to comment Share on other sites More sharing options...
SJC Posted November 19, 2015 Share Posted November 19, 2015 Don't bother with the Porsche studs, i'd buy some stainless ones from somewhere else personally. 1 Link to comment Share on other sites More sharing options...
987Monkey Posted January 21, 2016 Share Posted January 21, 2016 Looks I've got this problem, any tips or good tools for the job before I dive in this weekend? Will probably do both sides as from what I've read if one so goes the other is likely to be on its way too. Link to comment Share on other sites More sharing options...
DJMC Posted January 21, 2016 Share Posted January 21, 2016 Top tip: Wear eye protection! Tiny bits of sharp rusty metal abound in these situations. 1 Link to comment Share on other sites More sharing options...
Trickle Posted January 22, 2016 Author Share Posted January 22, 2016 On 21 January 2016 at 11:40, DJMC said: Top tip: Wear eye protection! Tiny bits of sharp rusty metal abound in these situations. Fear not, i am fully kitted out with PPE gear these days! I have the new studs and a flexible drill extension should the old ones need drilling out, weekend reserved for man time in the garage! Link to comment Share on other sites More sharing options...
DJMC Posted January 22, 2016 Share Posted January 22, 2016 Ah... silly me. I see you're wearing the eye protection in your avatar! Link to comment Share on other sites More sharing options...
@carnewal Posted January 23, 2016 Share Posted January 23, 2016 Having installed quite of few of these exhausts, the best way to remove the studs is to use an pneumatic chisel. You do need to support the flange though. 1 Link to comment Share on other sites More sharing options...
Woodhouse Posted January 23, 2016 Share Posted January 23, 2016 I had to drill out all 6 studs when I replaced my clutch. It was a complete pig of a job up on axle stands without a heat torch. Part of the problem is the studs are not only a press fit into the flanges but the heads are tack welded to the back faces of the flanges. Access to grind off some of the heads is really difficult, as is getting access to get the drill squarely aligned. I used an angle grinder, Dremel grinder, 90 deg drill with flexi drive and normal drill. I also disconnected the control arms to swing the suspension struts outward for adequate drill access. Lots of cobalt drill bits and cutting fluid needed! I recon the studs took me an additional 8 -10 hours. Without this problem the clutch/flywheel/rear main seal replacement would have been a doddle in a comfortable 6-8 hours doing it for the first time. We have another Cayman which could do with a clutch (heavy pedal) but there's no way I want to do this again. I'd rather pay £200 for domeone else to do this part. A few weeks later I had Gert fit his Carnewal exhaust. The best advice I have is to take the car over to Belgium, have Gert do the hard work and drive away with a great exhaust for around £400. Link to comment Share on other sites More sharing options...
Trickle Posted January 27, 2016 Author Share Posted January 27, 2016 (edited) Well, what a pig of a job! Gert (welcome!) and Woodhouse are not wrong above, it's a royal pain in the a**e getting the old rusted studs out. Edited January 27, 2016 by Trickle Link to comment Share on other sites More sharing options...
Founder Beanoir™ Posted February 15, 2016 Founder Share Posted February 15, 2016 1 hour ago, eponymoose said: Two questions for anyone who may have the answers. Which join / gasket is it exactly that commonly fails? And I don't suppose anyone can advise re the specifics of what studs one would need to order and where one might get them from - specifically referring to the mention of stainless steel studs instead of the corrosion-prone Porsche studs. Thanks. Both sides on my CS failed completely, the studs rust away and eventually the muffler/backbox flange breaks away from the down pipe/header. You can see where they join if you look through the back wheel. See the kind of triangular join just after the o2 sensors in this photo, with three studs...? So the chaps at Paragon told me they don't use Porsche parts to fit a new exhaust they use zinc plated studs with a longer life expectancy - I could find out where they get them from if you like, or ask Pete their service manager, he's a pretty nice guy. Link to comment Share on other sites More sharing options...
PorscheGT4 Posted February 17, 2016 Share Posted February 17, 2016 do the rear exhaust clamp which holds the tail pipes while you are at it, that will be rusted on also Link to comment Share on other sites More sharing options...
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