Not sure what the formal name is for it, but the bell shaped fitting on the northernmost tip of the exhaust line proper where it joins to the exhaust manifold: I have some not small leaking there. When I spray soapy water on that union (cold) and start it up I see copious amounts of gaseous molecules escaping. Too big even to form good bubbles in some spots. I think it's giving up more noise than I want.

I happen to have a quantity of lead sheating, sort of rolled up, it's real close to 1/16th inch thick. Lead melting point: 621 F. I was thinking to come up with a template - I'd use some stiff paper/cardboard, and make a template. It would look a bit like a smile, if about 3/4 wide, and stretched over 10 - 11 inches. That way when you wrap it on the inside of the bell thingy it will all be snug and roughly line up with the leading edge.

The hope is that lead is soft enough so that it will conform to imperfections and seal. I'm only partly optimistic that it will work. It's way softer than steel and softer than brass but that doesn't necessarily mean it will distort and do what I want upon tightening the bolts.

What do you think?

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1986 300SDL, 362K
1984 300D, 138K