Well that didn't go as planned.

broken o2 bung

 

Cut out 4-5 inches of that pipi, Buy new exh. pipe slip in place and weld it!

 

Never really thought about the fact that those would exist, but, upon reflection, I guess they have to.

Trying to remember if the original one is located on the end of a bend in the exhaust pipe. Meaning there may not be a flat stretch until much further down the pipe. I know those sensors are sensitive to temperature, but I don't know how much the temperature changes per unit distance in the exhaust system.

It might be less hassle, though a bit more expensive, to just replace the downpipe, as that is flange to flange to clamp.
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But I thought you said something about a California car. If the 2000 is a California car, NONE of the Walker products listed above will work with your vehicle. They are all federal emissions only. Supposedly at one time there was a bosal but I have not looked for it.

The issue with the walker pipes above is that the exhaust flange on California cars coming off the manifold has the bolts in a different rotation on the flange so the Walker parts won't line up at the manifold or shall I say the pre-cat and the inlet to the cat con at the same time. They also hit the stabilizer bar.

 

I thought that was the downstream O2 sensor ??

 

Also cooling fan not stopping and running all the time, WITHOUT any ECT indicated on the gage indicates an "open" in 2 wires under the battery area. Remove battery and box, carefully open up the wiring harness there is NO excess wire, you'll get 1 try. Think 1 was purple.
It's a fail safe design, if circut damaged/open...........cooling fan runs constantly, even upon start up!

 

It is the downstream O2 sensor.
That's right that the exhaust flange is different, that's part of why I did use the downpipe from the Cali car. Hits the stabilizer bar anyway. It had already started to self correct when it was in the '97 wagon (big dent).
I do still have the one from the 2000 and am going to try to patch it in from the cat back (where the Walker downpipe would have that connection to the cat section).
I'm too broke at the moment to get that really neat O2 pipe section. That would be the best way next to a complete new exhaust.
Just want this car back on the road so bad!

 

the exh down pipes are different. I grind off the weld on the flange, correct the clocking difference than re-weld the flange, no dent needed on pipe!

 

The 2000 down pipe is broken which is why I was hoping the '97 piece would work. The cat and O2 section are still good though, just would need to cut it past the damage as stated before.
As for all these truly good welding comments, not in the cards for me at the moment due to lack of skills, equipment and money to pay someone who does have them.
I've had to re-prioritize this project and work toward getting it fixed by next Saturday.

PS, the temp gauge issue was simply the ECTS not connected. I must have missed it when I was putting things together.

 

Managed to get the exhaust pieced together. It's not perfect by any means but it'll work for now.
Hope to get this car inspected sometime between tomorrow and Saturday and we'll be back on the road.

 

Outstanding!