Broken Tail pipe tip - Ideas??
 

Hey rotor heads-
Before I march off to re-invent the Wheel here, anyone have repair solution for THIS (pic). Seems the internal exhaust pipe that supports the External chrome tip has, well, evaporated.:sad:
This is the original part (yeeees I have a new muffler awaiting install. In Alaska...), and it fell off in my hand while washing the Beloved.
There seems to be enough solid "meat" at the rear of the muffler to support an addition that hopefully I could have welded (glued??) on, then screw back on the tip too it? This is temp of course, but need it too hold till I get al my #$%^&*! parts down from the Great White North. Next year.

Ideas appreciated!

Stu Aull
80GS
AZ

According to the 1979 parts manual, the piece that holds the tips comes off. With it off, it would be easy to weld a new support pipe back on. They call it the Funnel.

get someone to tack weld it to the can and not try to attach it to the rusted out pipe.

Racing Beat Powerpulse? You know you want to! Now that you're here in the desert, expect that's the last you'll see of that kind of rust.

Good luck on the repair,

If it looks like that on the outside then the inside is fucked. Unless.. its a salty snowy thing? Which i wouldnt know about being australianese. In which case, tack weld, riv-nut self tapping screw your heart out.

Ahhh. now that is worth a look, presuming the 30+ yr old Funnel hasn't welded itself to the muffler body. Will need to confirm 80 muffler is set up the same, which should be easy.
Thanks Lads. Gah! the perfect time to swapping in the RB system!!!!!!

Stu Aull
80 GS
AZ

I think KC is right and that end is removable. I'd just cut both inner tubes off (that other one doesn't look much better). I bet a short length of standard exhaust pipe could be welded back on to re attach the chrome sleeves too. Once apart, you can also access the inside of the muffler to repack / rebuild possibly.

The part that you guys are referring to is called the "diffuser" by Mazda. Its held in place by four 10mm bolts (6x1.0) and it is in fact replaceable and is a separate part from the muffler. It is a part that is still available as I ordered one not too long ago. You can order new tips and new screws that secure the tips to the "diffuser" and it will look like new. If I remember correctly the parts weren't that expensive.

I don't see them available at mazdatrix but they do have a nice graphic of the 80 exhaust that shows you the parts:

http://www.mazdatrix.com/pictures/ex...exhhangers.jpg

No joy - mine is of-a-piece. There is no separate end fitting. In fact, the rear mount bar is a part of it! Unlike what the Parts diagram shows. Obv an update in later production SAs.
I will need to modify it in-place on the muffler.
Thinking a muffler shop could chop the outer (rusted away) shielding that the Tips attach to and weld on a sleeve that is a smaller in diameter to the Tip, to the rear of the muffler, and attach the Tip to that...
hmmmmm. tiz a puzzle for a non-mech guy like me.:dunno:
Stu Aull
80GS
AZ

I believe that this would be your best bet. Hopefully you're able to find someone to help you out!

I just looked at my 1979, and the rear part the has the tips is tack welded in the the muffler. Looks like the process is to grind down the tack welds to be able to transfer to a new muffler when needed.

https://cimg5.ibsrv.net/gimg/www.rx7...516cbbb1f6.jpg

See the two bolts in the pic? There are two on the other side identical to those. Remove those 4 bolts and the diffuser will slide right out if the muffler. No need to grind any welds.

Argh is right Stu. At least you didn't lose it somewhere between here and Cali on the freeway! You planning to have this fixed in time for Saturday's drive??

That's why I'e been running an RB PowerPulse for the last 18 years... mine did the same thing. I saved the tips (still have them) but the funnel was a rusted mess & the bolts would not come free.
A decent shop could probably fab up a replacement funnel pretty easy, if you can get it off.

I would agree with Dave and Glenn. Two bolts on the top, two on the bottom and you have the end cap (diffuser) in hand. If its still available, I'd place one (2 for Stu) on order and just switch em out.

First off, again my thanks for everyone's input.
In spite the Parts Manual AND various Owners pix here, my SAs rear tail-pipe piece is not a bolt-on part (pic). Its a high-SN 80 production car, so am guessing at some point
Mazda said "F**k it" and started welding these to the rear of the muffler.
Happily I found a sweet little muffler customizing shop (ie, not a Midas) who had her up on the hoist and tack welded the tailpipes to the rear of the muffler in 10 min, no waiting.
Its not pretty if you happen to be laying on your backside under the muffler, but to the casual gawker, it will pass muster till I drag my still-in-the-box RB system (I hear you Glen!) down from Alaska next summer....

Stu Aull
80GS
AZ