Fixing a Bent Exhaust Tip?

[Ben]

Some Jackwagon apparently backed into my truck at work this morning. It looks like they hit my exhaust pipes with a receiver hitch (see pic below) and bent one of them in. I know there are expander tools specifically designed for this, but does anyone have any field expedient suggestions for repairing this without me buying a specialized tool and without cracking the metal?

I'd like to do this without taking the exhaust off as this is my diesel truck with the commie pinko diesel particulate filter built into the exhaust system, and uninstalling would be a pain. I also have to be careful not to bang on the thing like a gorilla, again because of the particulate filter. I don't need this to be perfect - I just want to get most of the dent out.

Any and all suggestions greatly appreciated.

[Monkeyleg]

Put a heat shield between the pipes and the car body, then heat the dented part to nearly red hot with a torch and bend the piece as close as you can to the original shape.

[cassandra and sara's daddy]

insert long round bar and roll it around to pull it out gradually

[Grandpa Shooter]

Take a large jaw Crescent wrench and tighten it until it just slips onto the tail pipe.  Apply slight pressure moving the wrench about a half inch at each tweak.  Repeat until the shape suits you.  CAUTION: Do NOT do this with the tail pipe hot or with the engine running.

[mtnbkr]

http://www.amazon.com/gp/product/B005FGLKVC/ref=pd_lpo_k2_dp_sr_2?pf_rd_p=486539851&pf_rd_s=lpo-top-stripe-1&pf_rd_t=201&pf_rd_i=B0002STSNU&pf_rd_m=ATVPDKIKX0DER&pf_rd_r=17MRX80YZ3QDQMY3Y053

[French G.]

Take a large jaw Crescent wrench and tighten it until it just slips onto the tail pipe.  Apply slight pressure moving the wrench about a half inch at each tweak.  Repeat until the shape suits you.  CAUTION: Do NOT do this with the tail pipe hot or with the engine running.

I'd start here, then use light hammer work to smooth it out. You need a round dolly to go inside the pipe to hit against, piece of round bar, the caps from oxygen/weld gas bottles often work if you have those, a really big socket will also work. Light hammer work!

[Hawkmoon]

Tail pipe expander. You should be able to borrow one from an auto parts chain outlet.

[mtnbkr]

Tail pipe expander. You should be able to borrow one from an auto parts chain outlet.

Cool, that's like the one I linked to above.

Chris

[White Horseradish]

Tail pipe expander. You should be able to borrow one from an auto parts chain outlet.

Every parts store lends these. There are two kinds - one that has a sort of a step and works for most pipe sizes and another that is more cylindrical and is for either larger or smaller pipes.

[Ben]

Thanks fellers! I'll try the parts store route and see about actually using the right tool for the right job. :)

I wouldn't be opposed to buying one for 20 ducats via mtnbkr's Amazon link, but the pipes are a bit bigger than that one stretches to. The ones that fit seem to run at least double that, which is a bit much for a one time (hopefully) use tool. If a parts store will rent or lend one to me, I think that's the ticket.

[Monkeyleg]

Who would have guessed auto parts stores would have a tool to lend specifically designed to straighten tail pipes bent by trailer hitches?

[drewtam]

I'd like to do this without taking the exhaust off as this is my diesel truck with the commie pinko diesel particulate filter built into the exhaust system, and uninstalling would be a pain. I also have to be careful not to bang on the thing like a gorilla, again because of the particulate filter. I don't need this to be perfect - I just want to get most of the dent out.

LOL

Wait till you see the Selective Catalytic Reduction systems we'll be adding. That is right- "adding" as "in addition to", not replacing.

I think the heavy duty trucks are already starting to add them. The machine makers will adding them over the next 5 years. I'm not sure what the time line is for these light duty/ passenger pick-ups.

[Scout26]

Sell this truck and buy a new one.  It's been ruined.

[Ben]

Wait till you see the Selective Catalytic Reduction systems we'll be adding. That is right- "adding" as "in addition to", not replacing.

You're ruining Christmas.

Do I even want to know what this is and how it will affect gas mileage? The f250s made in the year prior to mine without the DPF get like 6MPG more than me.

[Regolith]

What, nobody's said it yet?

Detcord.

[drewtam]

You're ruining Christmas.

Do I even want to know what this is and how it will affect gas mileage? The f250s made in the year prior to mine without the DPF get like 6MPG more than me.

At this point, it is still proprietary information. So I only know my own engines and haven't seen anything from competitors. You'll see the result in a few years.

[AmbulanceDriver]

I'm *really* glad my truck is a '96.....

[KD5NRH]

Is there a really seedy looking exhaust shop with an old fat guy running it anywhere near you?  Some of those guys are a lot more honest than they look, and will do something like this on a slow day for $10-15 just so you'll come back when you have real work to be done.

[Tallpine]

I'm *really* glad my truck is a '96.....

I'm really glad my truck is a '76.   

Just wish now that it was a 4wd ...   

[KD5NRH]

I'm really glad my truck is a '76.

Exhaust tips made from sch80 galvanized pipe? 

[Tallpine]

Exhaust tips made from sch80 galvanized pipe? 

Ha! 

There ain't no exhaust tip.  It ends at the output of the muffler right in front of the rear axle.