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Bosal 280-520 for 280z


Dave WM

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I noticed my OE muffler had a leak so decided to tackle replacing it. Only thing I could find that was near OE was a Bosal 280-520. this has a flange that goes from the Catalytic back to the muffler tip.

Cheap at only about 50$ with various discounts. 1st thing I noted after pulling the OE was the pipe from the flange back was not as long as the OE before making the bend down the diff. It was about 4" too short. I am guessing that the CAT converter on my CA car maybe short than a standard resonator. Since I don't have a resonator to compare its only a guess. Anyway bought some pipe and various fittings thinking I would fabricate a joiner and use U clamps to connect it all up. After sleeping on it, and think how hokey a bunch of U clamp  would look I decide welding was the answer. Now welding is something I have not touched since back in HS shop class back in the 70's and that was arc and gas, but figured it would be fun to try. Got a cheap 170amp HF mig and some gear to go with it, did not have enough gas to try the shielding gas so used the flux wire. Tried a few beads on the scrap pipe I had left over after cutting out the needed joining piece. Wow this is not easy, no granted I prob had everything working against me, cheap welder, flux wire, thin gauge steel , running a bead around a radious, but after a while I was at least getting consistent arcs and wire feed. I unplugged the ECU and put the pieces back on the car, using the big welding magnets to hold in place I managed to get a few tacks in place so I could remove and finish weld. I ringed it with small tack welds and then tried my best to bead it. I prob ground off 90% of my work and would re do until it looked like I had managed a solid unit. I pressure checked it with some soapy water, fixed a few leaks, painted the whole area with some high temp paint and reinstalled.

The fitment with the 4.5" added was perfect, too bad I had to add that extension. Exhaust was quieter than before (I would hope all this was done for a purpose) and I know the exhaust gasses are now all coming out of the tail pipe and not from the front of the muffler like before.

I clearly need to practice a LOT with the welder but it was fun and a nice learning experience. I cant recommend the BOSAL 280-520 only because I don't know for sure it would fit on a NON CA car, if it did then I would say its a great value. As is its still a good value if you have some welding ability.

 

 

 

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