Is there something wrong with Walker aftermarket exhaust parts? After just two years, I have cracking & leaking around the converter flange, and the over-axle pipe is perforated with rust. Or is there some trick to installing them?

They do salt the roads here. Oy, Vey! Do they salt the roads here -- sometimes it's applied with such enthusiasm that the roads are crunchy. To counteract this, I hose down the underside a few times each winter, when it's (relatively) warm. There's otherwise not a lot of rust under there.

I'm not opposed to an aftermarket exhaust so long as it doesn't cost a fortune or sound like a fart can.

1993 940 wagon, 99% factory stock, B230F naturally-aspirated inline-4 engine. All the factory brackets on the Y-pipe.

 

Installed a new exhaust system this week. Starla, this time. I'll report back on its longevity occasionally.

Initial impressions:
The Starla exhaust seems to be a lot quieter than the Walker ever was. I realize I was driving around with a holy exhaust system before, but when I first started the car, the impression was "Wow! That's quiet.". When I installed a new Walker exhaust in the past, it didn't make any impression at all; it was merely adequate.
The Starla mufflers seem heavier than the Walkers.
The Starla was easier to install. Everything seemed to fit better.

I thought I was meticulous about collecting all the little parts before beginning, but still missed one and had to make a middle-of-the-project run to the auto parts store. I suppose that's just about inevitable.
I forgot that the (Walker) converter pipe had rusted & broken off at the discharge end and that I had added a generic adapter to make up for the lost length. I think I'm going to buy a second one and put it on the shelf for the next time.

Does anybody have any idea why pipes break off at the joints? Does the swaging process create a ring of stress concentration that doesn't get relieved?

It was an easy one-day shade-tree job. Partly because I've done it before. Not just on this car but zillions of others -- I worked in a Sears garage while I was an undergrad and installed several exhaust systems every day. And partly because I used a generous coat of aluminum anti-seize compound the last time. I did the same this time, putting anti-seize compound everywhere two pipes came together. And on the manifold studs and hanger bolts. And on the driveway, my pants, my hands, my elbows, my shirt and even a smear on my forehead for good measure. (not sure how that last one got there)

Despite the short amount of time they've been installed, this job wasn't premature.

 

We used to install a lot of Starla brand exhaust systems on 240s. They whole system was less than $100 and took about an hour to install. Good quality.

 

Seems to have the same power & acceleration it had with an open pipe after the converter, suggesting that the Starla exhaust, despite being much quieter, imposes an unimportant amount of back pressure.

 

Two-year report:
The longevity of the Starla exhaust system has been much, much better than the Walker.
Definitely worth the higher price.

 

heavier weight means a thicker wall. Maybe more zinc coatiing.

My keyboard sucks...dangling keys and keys that don't press. Experience has taught me to keep my mouth shut about such things around my wife.