Stubborn exhaust leak?

Nick,

The stuck two-piece pipe could be affecting the alignment of the other slip joints and very well cause the leak. Disassemble the entire exhaust including the stuck pipes, clean and lube all insertion couplings and slip joints, and proceed as I suggested above. Don’t weld anything. The system needs to expand and contract. At this point I’d replace all the springs as well. No, an exhaust leak is not a typical characteristic of any well designed engine system. I can’t speak to other 912 installations. Mine had leaks from new for the first few hours after installation until I figured out the technique I described above. The 912 exhaust isn’t like a rigid car exhaust system where gaskets prevent leaks. It needs wiggled and aligned and snugged down carefully through trial and error until you get it just right.