Carl,
nothing in my XJ or S type is welded. I learned my lessons. Everything is clamped. And Jaguar never welded any exhaust parts.

not to mention that by not welding exhaust parts, you don't have to go to a muffler shop.

the tips are larger diameter than the resonator pipe by about 1/8" or 3/16". That difference is a big deal with exhaust tips, they should fit
almost tight, no more than 1/64th" play.

 

Almost there!!

following your suggestions, I found a steel pipe-connector at O'Reilly's that fits both the tips and the pipes. (they don't have stainless).

I cut two sleeves of 1-5/8" inch length each, as in the picture. Need to deburr them clean. Will be installing them with anti-seize on both sides.

 

Looking good. You might want to make a vertical cut the length of the tube. Then when you tighten the clamp there will be just a little contraction to tightly grip the exhaust pipe. If you coat it well with anti seize you'll be fine. I assume you don't drive it on snowy streets with salt down. It's like my old windshield seal, it doesn't leak because it never gets wet.

 

the clamp in the XJ-6 and XJ-S tips does not "close" like you would expect a normal round clamp would. It is basically a ring around the tip end, and then there is a Set screw which tightens the tip and clamp in place.by pushing the clamp "out" as you tighten it, something like that.

the two pieces I cut fit both the pipe and the tip perfectly, one outside and one inside, I was surprised at the perfect fit. The manager at O'Reilly's took the time to understand the problem and came up with the connector. I brought in one of the tips and the pipe measurement and he pulled out a boxed muffler which replicated what was needed.

So these sleeves are the "bridge" that was needed to make the two parts "mate". Thanks to you for the sleeve idea and to Brutal for the anti-seize idea.

I got involved in another project with the XJ-6 that I had not finished and because it is too cold to work on the floor, I'll wait to finish this S type mod in a few days. I will take pictures too.
.