Bad Exhaust Install?

**mugen_ctr** · 07-03-2011 08:26 PM

U definate need a donut gasket, or else it will leak.... if ur still using a OEM cat... aftermarket cats dont need a donut, a conventional gasket will do...... and using gasket for all exhaust joins with nut and bolt are a must... using a gasket sealing only prevents small leaks... if its like a opening gap where u can shine a torch into it and see in it, u need to realign ur exhaust so it sits flush... my brothers S15 has a massive problem with the exhaust not sitting properly, its a greddy PEii but, basically, the muffler to the mid section is out of align, and he needs to realign it, cause it still leaks to this day even with silicon and a gasket slightly

OR it could be that one of ur gaskets is just sitting loosely... i know its a bitch of a problem, i had similar problem, the donut gasket wasnt sitting properly... but pull the whole system off again, and reinspect it, than reinstall...

**NightKids** · 07-03-2011 08:55 PM

Just an update for everyone. The muffler itself has been ruled out. My friend put another muffler on and it was still making that noise. We suspect that it might be something internal. I have uploaded some pictures for you guys to look at including the race pipe which I was talking about. There isn't a flange where the race pipe joins the exhaust bit but the installer has put some red silicone thing there. Taking it out myself would be impossible as everything is welded on apart from the axle back and the race pipe bit. There's also a possiblity that the resonator is not big enough for the system??

**Super-DA9** · 08-03-2011 05:54 PM

when you say "race pipe" are you referring to the "flex pipe" (2nd and 3rd photo) or the "resonator" 1st photo?

because it is a common cause of bad exhaust rattle for the inside of the resonator to collapse, happened to my old DA and it sounded BAD haha.

from what you've said that really does sound like it. usually you can hear it if you hit the resonator pretty hard, or even jack up car, and listen close to the resonator while a friend revs it.

when you think about it, it can't be the headers, you've ruled out the muffler and any clearance issues to the chassis or heat shields, so that leaves you with either gaskets or resonator, and I believe it's most likely the latter.

**mugen_ctr** · 08-03-2011 08:26 PM

no offence man, but from the pictures, there welding is pretty sloppy, massive chunks, than in some areas, its bare....

could even be ur cat or resonator that have pieces of metal floating around... or worse is collapsed cat/resonator

**NightKids** · 08-03-2011 08:39 PM

The race pipe I'm referring to is circled in green. The red part is where there is no welding at all. There's just a bit of red silicon paste there.

So I need to take this somewhere else to get it fixed up. Obviously this dude aren't gonna fix this up cause his a douche.... can anyone recommend a good exhaust place in Melbourne that does good work? This may need to be cut & even rewelded...

**Limbo** · 09-03-2011 01:05 PM

from all the posts sounds like the baffle is stuffed in your reasonator. It looks like a cheapy also.
Those welds are really shocking, i've done better and my exhaust guy rewelded them for me cos he was embrassed by them!

It pays to get it done right the first time, that's why some shops charge more, cos they do a better job.

**Troy** · 09-03-2011 01:17 PM

Just did a Google search for you. Check this guy out. It even has sex in the URL! Unless you have already been there...

http://sportsexhaust.com.au/

**NightKids** · 09-03-2011 03:04 PM

Fkn dodgy bastard! I booked dandy exhaust for the weekend for them to have a look for me. The welds are pretty crap, i swear i wanna name and shame this place.

I'll tell them to have a look at the resonator for me...

**SuperJDM.** · 09-03-2011 03:20 PM

why did you have to make this thread on the same day i got mine done? now your stressing me out too LOL.
I was suppose to do dandy exhaust the first time but this place was half the price SIGHHHHHHHHHHHHHHH

**projectsti** · 09-03-2011 07:13 PM

Just pray that yours is ok or else you'll be crying!

**mugen_ctr** · 09-03-2011 08:35 PM

Originally Posted by SuperJDM.

why did you have to make this thread on the same day i got mine done? now your stressing me out too LOL.
I was suppose to do dandy exhaust the first time but this place was half the price SIGHHHHHHHHHHHHHHH

depends on what u got done... if u got the apexi WS2 universal muffler, they woulda had to fab up the pipe that goes over the control arm and the flange, but if it was just a cut of the old axle back an weld this onto the existing piping, i wouldnt worry to much... basically have a look under the car, if theres massive blotches of welded material, than its a shit job of a weld... or too little of it......it has to be a constant thickness of weld material all around for it to be a good solid weld

welding is like painting, theres no real easy way to go about it when u do it by hand... and a prime example was the one the op showed

**SuperJDM.** · 10-03-2011 07:06 AM

Originally Posted by mugen_ctr

depends on what u got done... if u got the apexi WS2 universal muffler, they woulda had to fab up the pipe that goes over the control arm and the flange, but if it was just a cut of the old axle back an weld this onto the existing piping, i wouldnt worry to much... basically have a look under the car, if theres massive blotches of welded material, than its a shit job of a weld... or too little of it......it has to be a constant thickness of weld material all around for it to be a good solid weld

welding is like painting, theres no real easy way to go about it when u do it by hand... and a prime example was the one the op showed

i got new piping from the cat, so i got a custom cat installed and from there new 2.5" piping all the way to the apexi WS2