zogster

This is weird - like I say, my local welder was quite sure that the 'bodge' flange was original, and that the cast iron flange had never been welded to the crossover. (Sure, he knows nothing about 944s, but I'm sure he knows his stuff re. welding. So when he said it was original, he's saying that whoever did it and whenever it was done it was a very good, proper job). And looking at the flange, I can't see any signs of it being welded to the crossover.

Is it possible that some cars were just made this way? It's an '87, RHD. (I don't see why the RHD part would affect this, as but I mention that for completeness)

I did think about picking up a new/used crossover... the 2-piece, to make all this kind of thing easier in future

zogster

Been looking on eBay and there's aren't any 2-piece crossovers available at the moment.

I do want to put it back together properly, but I actually couldn't persuade the welder I found to try and weld those two parts together!

So I think I'll do the best I can at re-assembling what I have, and hope that a little exhaust paste where the pipe fits into that flange will seal it. And I'll keep an eye out for a replacement 2-piece crossover

Mach 5

Here is a link to one for sale on Ebay. This shows you what it looked like originally. With all due respect to your welder, he doesn't know about 944 Turbo exhaust systems. When I brought my pipe to a very well known Porsche shop here in Chicago (www.midwesteurosport.com), they said that they see this all the time, i.e., that the square flange breaks off the pipe. When mine broke off, it was a pretty clean break, so I can imagine after years of use with it broken, it might be easy to think that is how it was made. But it is not.

The two piece crossover is nice (I wish I had one), but it doesn't effect the inlet pipe. It just makes it a lot easier any time you have to remove the oil pan.

http://www.ebay.ca/itm/Porsche-951-9...-/262562407241

zogster

Thanks Roger - problem is, that piece isn't any use to me unless I have the other side of the triangular flange also. Pic of my crossover attached...

Having looked at more pics, it does seem that however they were welded it wasn't a process that left an external bead/weld of any kind.

I may not have my terminology quite right here... I'm slightly confused that you say you don't have a 2-piece crossover, but the newly-welded piece that you posted pics of is what I understand to be the smaller of the two pieces in a 2-piece crossover. Is that not correct?

Are there more than two types of crossovers for our cars?

Mach 5

Ok, so both the inlet pipe and the crossover pipe have been modified. Here is what all your parts looked like when they came from the factory. There are triangular flanges that attach the wastegate inlet pipe to the crossover pipe (only one is shown in this photo). The square flange on the inlet pipe attaches to the wategate. I realize it's easy to spend other peoples money, but if it were me, I would get another crossover pipe and inlet pipe. Those parts may work like that for a while, but it would make me uncomfortable. I saw an ebay seller with a set listed for $350.

zogster

Ah, I think we're on the same page now, thanks...

I think Plan A will be to find a more specialised welder who might be able to re-attach the square flange properly.

Plan B will be looking out for a good used crossover at a sensible price.

And in the absence of either of those coming together before I want to get it back on the car, I'll use some exhaust paste in that bodged junction.

Bottom line is that while I'd like to put it back together properly, the bodged arrangement was clearly working OK for a long time, so a temporary fix with what I have is preferable to leaving the car in bits for too long. The fact that I'm doing this on the street (albeit a quiet one) rather than in a garage is a factor...

Mach 5

Yep, I understand. I am definitely a "function over form" kind of guy. If you can make it work the way it is, that's great. However, if after you get it reassembled, you experience any sputtering under boost, you'll know what the issue is. Don't bother chasing anything else until you get that replaced.

Good luck!

zogster

Cheers, I'll let you know how it works out!

zogster

So I found someone to weld it - an big independent Porsche specialist in West London. It did cost more than another welder quoted me, but they're familiar with 944s.

Pics attached... I realised when I picked it up that I hadn't specified that they should grind off the extra flange, so it's not as pretty a job as I'd have liked, but they're confident that it'll be solid and gas-tight, and that's what counts.