ALFAGTV6.COM

Hey, all!

Been a while since I was here ... busy year.

The white 1985 GTV-6 I bought back in January continues to thrill ... that is, when she isn't frustrating me with mystery problems! LOL

Last one was the rear brakes kept sticking ... finally turned out that the brake line on the drivers side runs too close to the exhaust ... when she would get good & hot, it would BOIL the brake fluid ... and cause the caliper on that side to stick shut ... ate-up the pads in record time ... the real booger was that it was a hard-to-trace problem, since as soon as the car cooled off & sat a bit the brakes would go back to normal.
(Anyone else ever experience that?)

A little heat-shielding and $700 later, and everything is back to normal! LOL

NOW -

The exhaust has been getting progressively louder all year ... little holes become big holes, you know.

I could look into patching, welding, etc, but what I want to know is what sorts of options everyone would consider for total replacement.

I know I can go to IAP and get a complete stock system for like $850 plus freight ... I also know there are some other options for pieces & parts (like the ANSA rear exhaust) ...

What is the conventional wisdom on replacing exhausts?

Obviously I don't want to spend a fortune if I don't have to ... but I am considering getting a new system if it seems like it is viable.

What other options are readily available aside from stock pipes? (That do not require massive modification?)

I should note that our area does NOT require smog inspection of any kind, so I could just say bye-bye to the cat, I suppose ...

All opinions and input appreciated!

VIVA GT !!!!

Hi Spike and welcome back. If I knew you better I would more likely tailor a more specific reply. As is, I'm going to assume you are a tight arse like me and want to stretch that dollar further.

Do this:

Have a scout around your local wrecking yard for a centre and rear muffler made of stainless steel. (From any donor not necessarily an Alfa)They are good for life so don't worry about them being used. They should be cheap. Be sure they have the same pipe ID bore size. Anything above 50mm ID should be fine. Preferably match your existing engine pipe ID.(The one entering the cat)

Take the el cheapo mufflers along to the your local mufler shop that has fabrication/bending tools. Get them to make up the necessary pipes around the mufflers you supply. Chances are you could recycle the majority of your own existing pipes with some cutting and welding here and there.

Any cheaper than that, you would have to make it all yourself.

The secret to an exhaust system longevity is temperature. Once the exhaust gases leave the ports they start to cool. Somewhere around the middle of the car, they get cool enough to reach chemical dew point. At this time the SO2/SO4 changes to sulphuric acid. The acid attacks the mild steel and causes corrosion. That's why the arse end of exhaust systems always corrodes out first.

Having a cat installed causes these same gases to maintain higher temps for a greater distance and is the reason why cars with emission controls have their systems last a lot longer. The cat also helps to burn off the oil fumes that Alfas love to pump out just cause they're Alfas and you get less of the smell getting back into the cabin. Good reason to keep it.

Using stailnless steel systems overcomes the acid attack problems. So does completely lagging the entire exhaust system with insulation which has the added benefit of keeping cabin temps cooler from radiant heat and not to mention boiling brake fluids !

Somehow, I don't think I have answered your question...but I hope I have provided some food for thought.

stainless is always the way to go when $$$ doesnt matter...scavangeing stainless bits is a good way to cut the costs