2nd Gen Non-Engine/Transmission Downpipe/Exhaust fix?

[CCiatteo]

Last night my exhaust system cracked and split at the connection just beyond the cast iron elbow on the back of the turbo. Pic is attached. The exhaust is of unknown origin but is a 4" diameter and appears to be stainless steel (cheaper version, not the real good stuff). I didn't realize such a choke point existed at the cast iron elbow (3" dia. ) and wondering if there are any upgrades I should consider before I simply remove my exhaust and the have the pieces tig welded back together?



Is there an upgrade to for the backside of the turbo to allow 4" all the way?



Is there a flexible connection available to prevent this from happening again? I am pretty sure this failed because the weld did not penetrate both pieces sufficiently and with all the vibrations, it finally failed.



Thanks for any and all input. I am kinda late to the 12v scene so I am sure this issue has already been resolved by someone.



The truck is stock internally and runs great.



Chris

 

[CCiatteo]

Downpipe/Exhaust - Update

Well after some soaking the joints and a BFH I was able to massage the downpipe free from the rest of the exhaust. So tonight I dropped the two pieces of at a friends shop to see if he can tig weld the two pieces back together. Turns out I was wrong on the material. The reducer cone is stainless, but the down pipe and the rest of the exhaust is aluminzed mild steel (magnet stuck to it). So we will see. Pics are attached and I really think the reason for failure was a poor weld. It appears as thought the weld did not penetrate both pieces, but instead was primarily on the stainless side. Hopefully tomorrow it will be one piece again, I miss my truck.



Chris