Joining Exhaust Pipes of the same size - options

[Uncle Buck]

I've decided to replace my 2 1/2" Magnaflow mufflers with Dynomax Super Turbos. I want something a bit deeper and quieter.


The issue is the outlet of the new muffler is the same OD as my existing tailpipe. What are the best options to make this connection. I don't want to weld it since a) I don't weld and b) as soon as it's welded I'll need to take it out for some reason.

Options I've seen

Use a band clamp designed for butt joints
Use an exhaust pipe expander and stretch the tailpipe making a typical lap joint
Use a coupler and clamp both sides

Others?

[Laffs]

Take it to a weld shop and have them put a V Band connection on the joint. Removable and will also seal up.

[RedSN]

I’ve got band clamps at my over-axle joint. Cheap and easy.

[xeninworx]

Yeah, just use band clamps. Can find a bunch on Amazon.

[ZR]

Don't use the sheet stainless steel type like this.


https://i5.walmartimages.com/asr/63b34a7c-d2dc-4d3d-b31f-dda424882373_1.dc69597023973ba0876f324bdcd2f216.jp eg

[ZR]

Need these heavy wall OE type like your S197 used. DaSilva's stock em, cheap n easy to use and won't fail over time.

https://static.summitracing.com/global/images/prod/xlarge/pye-hvc65_nt_xl.jpg

[Gabe]

Agree with the other recommendations, this type of joint is used in much more heavy duty applications such as pneumatic conveying of dry bulk materials (ie blowing dry powder from one location to another), which use 3 and 4 bolt styles for 6” heavy wall pipe. Very reliable.

[bbriann]

Yes band clamps work well, holding mine together. I have also been thinking about changing mufflers from magnaflow...I have heard at drag people tell me...your car is so quiet...compared open headers

[Scrape]

Another vote for good quality band clamps. I bought OE band clamps on one of my cars past. Worked like a charm.