O2 sensor hole rusted out

[RatLabGuy]

On my '93 beater Toy p/u... a little while ago I lost most of the exhaust while at Rausch creek.
Mostly rusted off, then helped a little by some rocks.
Before you lauigh - well, it is a Toyota so rust is par for the course .

I lost everything from the connecting pipe forward (cat, muffler, etc). Temporarily I have a muffler clamped on right there to quiet it down enough to be streetable...
But anyway, just after I clamped the new muffler on, the whole flange that the O2 sensor plugs into broke off, leaving the sensor dangling w/ a small bit of metal attached, and a nice big hole on top of the connecting pipe. I guess the newly added back pressure from the muffler was too much for it .

Whats the best way to "fix" this, w/o actually replacing that pipe. I'm sure I could find some pipe to wrap around it and clamp on to cover the hole, but I need a new flange for the O2 sensor.
Think it would be feasible to buy a bung and weld that onto a "repair" sleeve, then wrap that around the area w/ the hole so the holes line up?

 

[getstucksome]

I've welded in new bungs before. They worked fine.

http://www.napaonline.com/Catalog/C...erformance-Products/_/R-BK_3353686_0361130474

http://www.amazon.com/gp/product/B0..._m=ATVPDKIKX0DER&pf_rd_r=1RQC5TNEJQEWY7N9X0CD

 

[RatLabGuy]

OK now the magic question - anybody know the thread size/pitch for a 90s Toy O2 sensor?

 

[shawn]

If the bung fell out, no way you're welding a new one in. There isn't enough metal left in the stock tailpipe. You'll just burn through.

For the amount of work and trouble you're going to go through, I'm betting you can get a brand new pipe for under $100.

 

[shawn]

1993 TOYOTA PICKUP 2.4L L4 : Exhaust : PipePrice
WALKER Part # 42935
Extension Pipe
102.9" wheelbase; RWD; Base Model; DLX Model; SR5 Model; Fed. Emission; Optional Parts for Split System; If welded assembly, replace all required parts.

$13.47
WALKER Part # 42930
Extension Pipe
112.2" wheelbase; RWD; Base Model; DLX Model; SR5 Model; Fed. Emission; If welded assembly, replace all required parts.

$20.79
WALKER Part # 43313
Extension Pipe
121.5" wheelbase; RWD; Base Model; DLX Model; SR5 Model; w/o California Emissions; w/ Xtra Cab; Optional Parts for Split System; If welded assembly, replace all required parts.

$23.99
WALKER Part # 42906
Extension Pipe
102.9" wheelbase; 4WD; DLX Model; w / Standard Side Bed; w/o California Emissions; Optional Parts for Split System

$26.79
WALKER Part # 44066
Extension Pipe
121.5" wheelbase; 4WD; DLX Model; SR5 Model; w/o California Emissions; w/ Xtra Cab

$28.79
WALKER Part # 45410
Front Pipe

121.5" wheelbase; 4WD; DLX Model; SR5 Model; w/o California Emissions; w/ Xtra Cab
102.9" wheelbase; 4WD; DLX Model; w / Standard Side Bed; w/o California Emissions

$61.79
BOSAL Part # 790235
Front Pipe

4WD; XLWB; Model code: RN110; Excl. Cal Emissions; DLX Model; Base Model
4WD; LWB; Model code: RN106; Excl. Cal Emissions; DLX Model; Base Model
4WD; SWB; Model code: RN101; Excl. Cal Emissions; DLX Model; Base Model

$71.79
WALKER Part # 45405
Front Pipe
112.2" wheelbase; RWD; Base Model; DLX Model; SR5 Model; Fed. Emission; w / Standard Side Bed; Requires 31564
102.9" wheelbase; RWD; Base Model; DLX Model; SR5 Model; Fed. Emission; Long Bed; Requires 31564
121.5" wheelbase; RWD; Base Model; DLX Model; SR5 Model; w/o California Emissions; w/ Xtra Cab; Requires 31564

$90.79

 

[RatLabGuy]

Just to clarify - I was suggesting welding a bung onto a sleeve (maybe a bigger pipe cut down the middle), the wrapping that around it as a repair.
Mine is the LWB, the more expensive connecting pipes... and of course the bolts at the top are trashed so I'm not eager to delve into that. But may have to.

Its hard to get motivated to spend money on a free truck that has no value anyway.

 

[transman731]

you can put the bung anywhere, it doesn't have to be in the same place. it's size is 18x1.5

 

[shawn]

Its hard to get motivated to spend money on a free truck that has no value anyway.

An hour of dicking around with a paper thin, rusty old tail pipe might fix that for you.