My connection joining the catalytic converter to the header is shot.

For the first time I am getting a bubbling exhaust noise, which I am guessing will get a lot worse in the very near future.

​​​​​​The rest of the converter and header look solid. My question, what are people doing about this area on these old cars ('93 940T)? Source and purchase a new header, converter, and bolt kit? Or cut and weld them together instead? Other options?

Thanks for any input as I plan my next step.

 

You pretty much mentioned all options, there is no more. It just depends on how much you want to spend or do the work yourself. Getting used parts would be the best if you can source them.

 

What if I cut off both flanges and used a simple exhaust coupling with two clamps? Are the pipes too thick for a clamp to be effective?

 

I doubt a clamp would do it, it doesn't look smooth enough with all the rust, hard to say from the photo.

 

Purists please turn your heads. I went with a local shop. They cut out the flanges on both the converter and the downpipe header and welded a segment of 14 gauge pipe between them (Volvo sections are 16 gauge). Then header paint was applied. Cost me $82. Now I have one continuous exhaust unit from the turbo to the first muffler instead of two. Car is as quiet as a mouse now.



Literally the minute I returned home with the car, Bill Eidson at Voluparts replied to my email. He has a used converter, downpipe, gasket, and bolt kit all for $175 plus shipping, in case anyone else is looking. This mod is now the second permanent change from factory on my car - the front leather seat covers were replaced a few years ago to keep the wife happy while driving a 30 year old car every day.

 

Not a bad solution... and nothing wrong with driving a 30 yrs old car--much better that the new junk!