Catalytic Converter/Exhaust Pipe Repair Options

The connection of the exhaust pipe to the first catalytic converter rusted apart this past weekend. Trying to determine my options. I haven't had any issues with the cats yet, though they are presumably original and 227k miles old. I know best route would be to replace the entire line but could I get new piping welded in between the two cats and try to keep using the originals? I wouldn't mind bandaiding this problem for now as this is just for compliance (I'm in Wisconsin). The muffler and exhaust pipe were replaced about a year ago by the previous owner so that is in pretty good condition. Finally, if I do go the route of getting a new entire line with Cats, how can I go about salvaging the second O2 sensor? The nuts and bolts are almost entirely rusted away. Any suggestions for replacement cats also welcomed. Thanks!

 

Now the problem starts with Could I get a pipe welded in to patch things.

If you could do the work I say go for it .

Till you repair things the correct way the labor is going to get expensive

just replace the pipe between the two cats that gives you all new parts to bolt together

to remove your O2 sensor just cut off the studs

Good luck!!

 

Just went through this. Everything sorta went out at the same time: Headers cracked in half so I replaced it with OEM. Then the muffler had rusted holes and started leaking so I replaced it with OEM. The the O2 sensors were rusting out at the base and the gaskets between the cats were leaking.

I tried to do it piece meal, but in the end replaced the entire system brand spanking new with OEM... everything including hardware. Its easy and everything just bolts up. Was expensive but it will last another 20 years. Sold the used Cats to a recycling yard to offset the price of the new ones.

O2 sensor nuts can be filed down with a small file to make them straight and then take off with a small wrench. You can torch off as well if you have access to one.