Exhaust Clamps: What Clamp Is Best for Your Application
Exhaust Clamps, A DIY Exhaust System Builder’s Best Friend
For those that are looking to add an aggressive performance exhaust note to their modern muscle car, or those with newer trucks, have it pretty easy when it comes to performance exhaust systems. Installing a pre-made mandrel bent exhaust under one of these is a Saturday afternoon job at best. Now on the other hand, when you’re talking a classic muscle car, hot rod, or pickup truck, especially one with a modern suspension under it and possibly an LS swap, Coyote swap, or other non-original engine, well, then getting a full exhaust system under it is a bit more difficult.
With these examples you will rarely find a complete bolt-on exhaust system unless it is an extremely popular chassis and suspension combo with a common engine swap. So, for the majority of such hot rod builds you’re going to be starting with a universal dual exhaust kit at best, and possibly even working with bulk exhaust tubing and your favorite pair of mufflers to get the job done. In these installation cases you’ll need to source exhaust clamps to fit everything together. This guide will explain each type of clamp and its intended use to help you build the right exhaust for your ride.
What are the Different Types of Exhaust Clamps?
The diameter of the exhaust clamps your system requires isn’t the only decision you’ll need to make when looking for exhaust clamps for your exhaust system build project. While that will undoubtedly be your first “click” on your search path, once you’ve narrowed your search to the proper size then you’ll need to determine the proper clamp for your needs. Below we have listed the four major styles of exhaust clamps, how they work to seal your exhaust system, and the main application they are intended to be used with. We hope this will help in your decision as to what is best for your application.
Saddle Clamps
The saddle clamp, more commonly known as a U-bolt clamp, is the most common muffler clamp found today. The U-bolt exhaust clamp is used at most every exhaust installation center across the land and can be found hanging on the wall at repair shops and auto parts centers everywhere. The saddle clamp is available in mild steel and stainless steel, the U-bolt saddle clamp style of exhaust pipe clamp features a pressed/folded saddle and U-bolt clamp that slips over the exhaust pipe slip fit connection and passes through the saddle where nuts and washers allow the U-bolt clamp and the saddle to tighten around the exhaust pipe’s ID-OD slip fit.
The traditional U-bolt saddle clamp is a low-cost solution that seals by slightly deforming the tube connection as the clamp is tightened. This creates a very solid leak free connection, however it does not provide easy serviceability if the system component (muffler, tailpipe, etc.) needs to be removed for some reason, such as dropping the transmission. We recommend using the U-bolt exhaust clamp only for components that you do not foresee needing to be removed on a regular basis. Note, you can add a second muffler clamp opposing the first one to further help secure and seal the exhaust connection. Lastly, the traditional U-bolt style of clamp is often used in conjunction with hook-style exhaust hangers for a “no weld” hanger mounting solution.
Narrow Band Clamps
You will find narrow band claps are used on stainless steel exhaust tubing and are indeed stainless steel themselves. You will find this style of muffler clamp in OE exhaust connections as well as part of stainless steel “cat back” kits sold for popular vehicle applications. These band clamps provide a high sealing solution but are generally reserved for special stainless steel slip fit connections that are cut/machined with slots to provide even clamping pressure around the circumference of the joint.
The design of the narrow exhaust band clamp allows for easy disassembly and the clamp can be reused. While more costly than a traditional U-bolt style muffler clamp, it is often a much better solution for stainless steel slip fit connections. The narrow band clamp is also usually more compact than the standard U-bolt clamp, fitting in tighter confines under the vehicle and can be positioned appropriately to provide a cleaner under car appearance as well.
Tube Band Clamps
The tube style exhaust band clamp is like the narrow band clamp but is constructed from a thinner stainless steel material that allows it to conform to the pipe union. This allows the tube band clamp to aid in sealing without needing any special relief slots cut into the pipe material to aid in sealing. These clamps are available in several styles, including slip fit (or lap joint) and butt joint pipe fitment. The butt joint pipe fitment version allows two pipes of the same diameter to be joined without having to use a pipe expander or other methods to create a slip fit connection. The slip fit tube exhaust pipe clamp has a step in the design to allow the wider muffler clamp to not only grab the exhaust pipe, but the larger section of slip fit (often found on mufflers or pre-made slip fit tubing) that goes over the main exhaust pipe.
These tube style band clamps will often create a “memory” as they are tightened on the exhaust pipe connection, which aids in sealing. These tube type band clamps are reusable; however, the clamp’s memory can often cause exhaust leaks if the pipe or muffler being serviced is replaced with a new piece where the dimensions are slightly different from the original piece the clamp was used on. Furthermore, due to this memory effect, it is critical to place the clamp in the exact same location on the exhaust pipe connection to maintain a good seal. The tube style of exhaust band clamp is usually found to be a higher cost clamp than the narrow exhaust band clamp, but as noted, is usable on exhaust tubing without any special modifications required to the tubing to aid in sealing like the narrow exhaust pipe clamp.
V-Band Clamps
Lastly, we have V-band clamps. A V-band exhaust clamp requires welding their special flanges to each side of the pipe union, then the special wedge clamp is placed over the two adjoining flanges, sealing them together as the clamp is tightened. You’ve no doubt seen V-band clamps used in high boost applications to secure exhaust down pipes to turbochargers and even for the turbocharger to engine connections to prevent blowing the tubing out of the silicone couplers under extreme boost. That said, many builders are moving to the V-band exhaust clamp design for their entire exhaust system build. While the V-band exhaust clamp is often not much more than the tube style exhaust band clamp, they do require welding. We’ve seen V-band clamps used for tailpipe connections and other under car exhaust use.
It’s simple really, if you can weld, the V-band style of clamp offers the highest level of reusability and sealing for just a bit more labor during installation. V-band clamps come in stainless steel, while the sealing flanges come in both mild steel and stainless steel compositions. You will find most sizes are in stainless steel since V-band clamps are so popular for high heat applications like header collectors, turbo manifolds, and more. Most V-band clamps on the market seal directly on the flanges via interlocking machined grooves. This allows exhaust system components to line up and fit perfectly time after time, perfect for racecars or other applications where the union will see regular disconnection and reconnection for driveline servicing and other needs.
Helpful Tools and Accessories for Your Exhaust System Build
Sometimes you need to tweak an exhaust pipe opening, or perhaps you have a pipe fitted to your project car and would rather cut it in place versus completely removing it cut it using your bench top power tool. Whatever the reason, these exhaust system service tools and accessories will help your project go more smoothly.
