1990 Volvo 240 DL Sedan. Location New England.

Six years ago, my mechanic welded a broken connection from the header pipe to the inlet flanges at the catalytic converter. This saved the cost of replacing both the header pipe and converter. The weld has not failed since.

For the last two inspections, my mechanic noted that the front exhaust down pipe is getting rusty. The section of this pipe that connects to the manifold is rusted and pitted from the bend up (see picture). I looked at it; it appears to be solid with no weak spots. But I’m not a mechanic.

The catalytic converter is still okay. Both the header pipe and converter may be original equipment on the car.

If the header pipe must be replaced, then given the once failed and now welded connection to the converter, it probably makes sense to also replace the converter, even though it is still okay.

I don’t like to replace parts before it is necessary, and would opt to try a solution like I did 6 years ago with the welding before investing in new parts.

Given the current state of the header pipe, is there any way for me to extend its life?

Or might the header pipe be okay for a few more years in its current state, so just wait until there are holes in the pipe?

I realize that without seeing the pipe, this is difficult to answer. I'm just looking for whatever thoughts folks might have.

NOTE: I am currently replacing the exhaust system from the converter back. But I don’t see this as a reason to fix something that right now is not broken.

NOTE: Nlot sure how to include 2 pictures. Picture 11263 in the library is a better picture, but the pitting does not show up as well on it.