Is there a replacement pipe out there that is either flanged to mate with the header pipe like a catalytic converter? Or a header pipe the is long enough to mate with the first muffler. I seem to recall something but cant seem to find it. Possibly from the 140 series before the cat was in play.
Starting May 1st in NJ no more sniffer test on Pre-95 vehicles hence no more inspections required. Pipe coming out of 3.5 yr old cat has separated at the weld. Bosal cat purchased from Tasca Volvo. Will have to replace the whole F&^$@&G system again.

That part is, if it can be found, for a B21.

I looked for it and cud not locate a source.

I found and bought a "non cat" 1976 front pipe for a B21 ...new...from that Georgia parts source. $85, pull shipping....which was expensive due to the length of the part.

http://www.voluparts.com/

it runs from the header all the way to the first muffler. There is a "can" where the cat would sit..

Don't know if it will fit a B230....most likely not.


I've got Historic Plates so there is no longer any inspection.

I did this on my 1980 with a B21

if you can mig weld or know someone who will for you, the problem is easily solved for about 20 dollars.

if you you can let me know, if not there is no point writing out the specifics

Hey Richard I did have the cat rewelded temporarily with the electric one. It wont last im sure so looking for another option.

first you remove the old cat leaving a gap between the front muffler and the header pipe.

1. measure this gap and add 6" or so to the length
2. accurately measure the outside diameter of the front pipe
3. accurately measure the inside diameter of the header pipe
4. obtain from an autoparts store the appropriate length of pipe of good heavy gauge steel that has at one end a flare to fit over the outside DIA of the front muffler pipe and at the unflared end is suitable to fit inside the header pipe
5. also buy an o2 sensor bung at the auto parts store
6. buy an exhaust seal ring of suitable size to fit around the unflared end of the pipe you bought

(http://www.amazon.com/Volvo-Exhaust-Starla-Brand-1266118/dp/B00AFBNPKQ)

7. purchase a 2 or 3 hole exhaust flange depending on what is on the header end and slide it on the unflared pipe end
8. slide the seal ring on the unflared end of the pipe such that 1-2 inches of pipe extend beyond the seal ring and the exhaust flange behind it
9. carefully tack weld "multiple" times around the seal ring so it is affixed to the pipe on the inside end (header side)of the pipe (or cleanly weld a bead around 100%, your choice)
10. now drill a hole in the pipe roughly where the o2 sensor would be if the cat was there and weld the bung on the pipe over the hole
11. install the flared end of the pipe over the front muffler pipe and slide the 2" extentsion end into the header pipe

clamp it up and you're done

PS: if there is slight angle between the end of the header and the front end of the muffler pipe you can utilize the curved section of the cat pipe in back of the cat in you fabrication to help in straightening out the run of pipe you're building

Great plan, even easier as my O2 sensor is located in the exhaust header original still.

Yes, there is a replacement pipe for the cat---I have one on the shelf saved from a scrapped car. 1976-77 (maybe later too) non-California, non-LambdaSond cars had a front pipe that extended to the front muffler. 140 pipes have a flange of the right shape but the flange on a B20 sits parallel to the ground -- and at the muffler end the pipe angles upward.
I wouldn't be so fast to do what you propose before researching the move better knowing how "picky" NJ is with their state run inspections. If your car still will need some sort of safety inspection I would imagine removal of pollution equipment may be a reason to fail.
Another factor--where does your O2 sensor sit? -- Dave

Hi Dave no more sniffer test which is all they inspect anymore. I will get a sticker which states "no inspection required". Remove the old inspection sticker as well. My problem is the shop welded the connecting pipe to the cat on install its an IPD sport exhaust cat back system which is still in good shape.