I have finally given up with repairing the rear exhaust boxes on my Jaguar XJ6 X300 and have purchased the rear four boxes in stainless steel.  I bought them from G.E.S exhausts for £510 including delivery and VAT.   As I have said in one of my previous articles about the cracked down pipe, the first sections of the exhaust contain the catalytic converters and I believe they are made from stainless steel (the boxes, not the catalytic converters). 

GES exhausts said that they could provide new tail pipes at extra cost, but said that most people just re-use the original stainless steel tail pipes.   To keep costs down, thats what I decided to do.

Now I just need to find some time to fit the pipes.  Hopefully I will be able to do this myself, I just need to get the car high enough to be able to manoeuvre the pipes through the rear subframe.

Here are a few photos of the new ones just after unwrapping them.

I decided to have a go at fitting the exhaust myself by jacking the car up and hoping that I could get sufficient height to manoeuvre the exhaust into place.  After cutting the drivers side boxes off using my air saw, it didn’t take long for me to start thinking that I should have taken it to a garage.

The boxes and pipes containing the CATs were still in good condition as can be seen above.

The problem I had was threading the pipe over the rear drive shafts.  I needed to lift the car quite high before I was able to get the angle I needed to get the pipe in place.

The photos on the left and below show the drivers side in place.

Once I had got the drivers side in place I was happy to cut the passenger side boxes off.

Where the pipes pass over the drive shafts, there is a rubber mount on each side.  There is a pin on each exhaust that passes through the rubber mounts.  This pin needed transferring from the old exhaust to the new one.

Here I was passing the pipe over the rear drive shafts.  This is where I needed the extra height to get the correct angle.

Both exhaust pipes connected to the catalytic converters and fastened with clamps.

Both pipes fitted.

The original tail pipe taken off the old exhaust and fitted to the new one.