db/sb

Here's how one of our members solved that problem:
https://www.chevyhhr.net/forums/how-tutorial-library-21/how-repair-flex-pipe-31536/

843de

Good find there db/sb, I was looking for that to link up here.

AJochum

Nice! What I like is (if I'm reading it right) is that the bolts line right up with the exhaust manifold of the HHR.
Someone could make a LOT of money if they just produced what he did but all fitted.

By the way - getting those three nuts off is a bear. Not a ton of room under there, especially without a lift and mine are totally torqued on tight. Will require heat and double-jointed arms.

db/sb

The part exists but you'll still have to do some cutting and welding. Or have it done. I found these but I stopped my research when I found out that Chevy would fix ours under warranty. Here's a couple of links to them:

http://www.theflangeman.com/cgi-bin/...ion&key=FX2060
http://www.ebay.com/itm/Chevrolet-Co...item3cbf0dd071

AJochum

Thanks for the leads. Monday I'm going down to my dealer and see if he can run it through warranty. If not, think I'll buy one of those. It would seem that it could be installed pretty easy, especially if they oversized/undersized the tubing so you could cut the pipe, slide it over and clamp it.

donbrew

When I replaced the down pipe/cat, I had no problem getting the nuts off. I just put the car up on jack stands and used a 24" extension, if you are laying on your back it is a straight shot. The problems come in dis-connecting the electricals, that is a B.

You DO need to have a flexible section in that spot,