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Cutting stock exhaust off with Reciprocating Saw

19K views 20 replies 16 participants last post by  AdeptPunk38  
#1 ·
I'm going to be installing my new Bosal this weekend and I know that I have to cut the stock exhaust - - I've done a number of searches on the subject and picked up a number of very helpful hints from many of you. The question I have is: Has anyone used a reciprocating saw to make the cut with? If you don't know what kind of saw this is, then you haven't done it. For those that don't know, this is a power saw in which the blade sticks straight out - - used primarily for such things as cutting a whole in a wall for a window. However, with he right blade I don't see why it can't be used on the exhaust pipe. Anuone with any experience in this?
 
#11 ·
Here's some useul stuff I found from myfordfocus.com. Cut here and other images.

With the warmer weather I was hoping to do this soon too. I bought my exhaust second hand, was it supposed to come with gaskets or anything? I just have a short bolt and nut and a couple of 'U' shaped bolts (hangers?).

Will putting this together be pretty obvious once I get under the car?
 
#13 ·
Those pictures were great. Thanks. The u-bolts you're talking about are probably the clamps that go over each joint. As far as installing on the Focus . . . its been a long time since I've worked on mufflers and exhausts, a very long time. But I do remember that it was relatively easy to hold one in place if you had some imagination and were close to a hardware store. However, if the one you boght came off of another Focus my guess is that it will fit in pretty easily. Exhausts are one of those things that if you just get under the car, look at it, think a little bit, and you'll find that you can put it together relatively easily. At least I'm hoping that's the case with mine. Good luck.
 
#15 ·
If you might make more than one cut in an exhaust pipe in your lifetime, I reccomend getting a real exhaust pipe cutter like the one craftsman makes.

http://www.sears.com/sr/product/summary/productsummary.jsp?bidsite=CRAFT&pid=009476070 00

That one's got 4 cuting wheel things and the handle tightens the tool around the pipe. You just rock the tool back and forth a few times, tighten it, and rock it back and forth a few more times. You'll end up with a really nice, clean cut, ant the tool only costs about $20. These things are great as long as you've got room (which is almost always the case).

If you cut your stock exhaust apart cleanly, you can more easily put it back together if you end up trading the car or whatever... (get a 98 cent coupler and 2 clamps at your local auto parts store or a $10 borla stainless steel band clamp - those things rock)

[ 03-15-2002: Message edited by: cloudmaster ]

[ 03-15-2002: Message edited by: cloudmaster ]</p>
 
#18 ·
You can't beat power tools! I used a cordless sawzall to cut my old system. I cut it where it passes over the suspension so the system could be used again just by using an adaptor and some clamps.

If you cut it on a bend, then it is very difficult to reuse the stock system without a leak.

Just a thought.

Tony D
 
#19 ·
I couldn't wait, I started tonight just to give me less to do on Saturday. The saw worked great, cut that exhaust pipe just like somebody here said it would - - hot knife through butter. I took of the resonator too. it was easier to cut the metal hanger than to try to pry it out. Took off the hanger (it slips out with a simple twist), put it in a vice on my handy portable workbench and cut the metal nipple off. Put the car ramps together and called it a night. Tommorrow I start on the rest of it. Afterwards, I get to try it out driving to a Blue Jackets hockey game Saturday night. I hope the car ramps hold up - - the box showed a big old pickup truck parked on top of them. I wouldn't look good smashed on my garage floor, besides I'd miss the game then. The car isn't a year old yet and the resonator was already beginning to rust. This would be a lot easier to do if I hadn't pulled the muscle in my left cheek this morning - - and it ain't the face cheek muscle I hurt.