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What I learned at Mid America, Exhaust failures


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OK, whats with the exhaust on our cars. Several folks had mufflers fall off, resonators fall off etc. Lots of weld failures on the exhausts. It seemed most were cars with headers. i have a header and like to keep my exhaust on.

What are we all doing incorrectly?

Brad Fenn (AKA McGyver) wondered if adding a piece of the flexible stainless braided exhaust hose to the system, the kind often seen on front wheel drive cars, could help. Maybe added between the downtube and the resonator?

I'm not as dumb as I look

74 Verona

06 Audi A3

09 Mercedes C300

06 VW Passat

03 VW Conv Beetle

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Yeah, it's really weird. I recently got under my '69 and found that the glass pack that is in the middle of the exhaust system had cracked almost all the way around! It was a really odd place of it to crack too. Luckily I caught it before it broke off while running down the highway or something! I think this one though is due to not having a mount near the middle of the system. The stress was just too much...

ClockWise MotorSports

'69 '02 Rat Rod O=00=O

'62 Chevy C10 w/SS 327

'63 Datsun 1200 pickup

'71 Datsun 510 Race Car

'70 Datsun Roadster

'78 Kawasaki KZ650 Street Cafe project

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lack of the correct support bracket with

all if it's spacers, rubber insulators,

special large washers to absorb the negative vibs.

poor installation alignment / assembly

lacking the 'correct' rear rubber donuts

with the nylon reinforcement inserts

to eliminate negative vibrations,

and to allow movement

poor quality parts

poor welding

'86 R65 650cc #6128390 22,000m
'64 R27 250cc #383851 18,000m
'11 FORD Transit #T058971 28,000m "Truckette"
'13 500 ABARTH #DT600282 6,666m "TAZIO"

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If your running a header, flex pipe added between header and exhaust. I too had a similar breakage on a stretch of I-5 in Seattle. Had to find a coffee can at a convenience store. Haven't had a problem since running flex pipe. Almost everyone I know here that has a header runs one.



Squatch Pads

Lorena Texas

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Exhausts on 2002's have to be braced to the transmission, and

you need to give them room to move.

I've had all the failures you note (including the radial cracks)

and the fix was simply to (wait for it)

let the tailpipe hang down further. (on an early car)

after that, all the suspension points for the muffler need to be good,

and leaving the 3- bolt clamp at the downpipe just snug, not hella tight,

is always good insurance. You can always tighten it a bit more,

but driving home with a coke can wrapped around the resonator sucks.

We did the flex pipe thing a while back- can it take twisting?


"I learn best through painful, expensive experience, so I feel like I've gotten my money's worth." MattL

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