Flex pipe repair VW Passat

The flex pipe on this 2000 VW Passat was damaged on a speed bump. Local muffler shops wanted over $100 to replace it. It made a nasty noise.

We obtained a replacement pipe from Summit Racing for $13:
http://www.summitracing.com/parts/JEX-FLX2004B/

This joint was exactly the same size as the original.

I used a reciprocating saw to slice out he old joint cutting through the welds on each end. I then used a grinder to open up the gap until the new joint was a tight fit. Leaving the original welds in place added thickness to the pipe making it easier to weld without blowing holes in the thin pipe.

I used a MIG welder to weld the front of the pipe in first. Then I had to force the rear pipe into alignment with the flex coupler while I made a tack weld. Then, I finished off the weld around the pipe.

The repair was surprisingly simple once we found the right replacement joint. It was not available at any local parts store. I already had a welder but I could have bought one from Harbor Freight plus the joint for what the muffler shops wanted to charge to make the repair.