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Old 07-13-2002, 03:09 PM   #1
GooseMan
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Unhappy EEK! Exhaust help!

I recently bought a used Brullen muffler (just the rear section, I already have a 2.5" mid-pipe) for my MY00 RS. Usually, you need to buy the ENTIRE Brullen cat-back kit, cause the Brullen mid-pipe is longer (thus, the muffler section piping is shorter) than stock peices. So a rear muffler section isnt a direct replacement for the stock peice.

So I had the unit modified at Brullen themselves. They brought in an RS, custom welded some new piping to make it fit the stock exhaust locations.

Me and a friend of mine went to install it last nite. Everything fit perfectly! The tips were perfectly centered in the cutout on the bumper, there was enough clearance everywhere...everything was fine. Besides the fit and finish, it sounds AMAZING (its the quiet dual-tip, 2.5" piping). I was happy.

But when I drove my car off the ramps, I immeadeately noticed this weird vibration and noise. A strange rattling right underneath my passenger seat..right where the muffler bolts up to the mid-pipe. I figured it was just the exhuast rattling against the heat shields or something.

But I just brought my car in, and jacked it up to check it out. First off, the muffler moved abaout an inch or so towards the passenger side, so that both rubber exhuast hangers are almost being stretched to their limits. And the muffler is touching the heat sheild! Also, the piping is touching (or barely touching) the drivers side CV joint (where it meets the diff...the green part). And it touching the rear suspension X-member.

and

how the HELL did this happen? Everything fit perfectly fine until I drove it. How the HELL did everything go so outta whack?!! Besides the fact that the rattling is annoying, I'm worried about the rubbing with the rear CV joint!

Any ideas?
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Old 07-13-2002, 03:20 PM   #2
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My exhaust "walks" while driving too...though doesn't move as far as you've described. Every day I notice my muffler has moved over towards the rear diff...and every day I move it back.

One quick check...did you put back all the exhaust hangers? Maybe the one on the midpipe isn't connected...there should be three total, one on the midpipe, two on the can.

The stock rubber hangers are VERY soft...too soft if you ask me. I'm going to invest (someday) in some stronger ones.

That's all I can think of... sorry!

NC
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Old 07-13-2002, 03:54 PM   #3
subawang
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one thing that may help is getting the polyurethane hangers from cobb tuning. I think they are like $10 each or sth. At least they won't stretch as much as the stock rubber ones. LaterSSS
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Old 07-13-2002, 03:58 PM   #4
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Yeah, or the Ion Performance ones...(same thing...just sticking to Canadian pricing)

I still dont get how EVERYTHING went outta what like that. Right after it was all bolted up, everything sat perfectly fine. After turning it on, it just went outta wack. All he hangers seem to be hangin OK, tho...theyre just off to the right!

Very ODD!
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Old 07-13-2002, 04:06 PM   #5
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Could have been the RS they used to mock up the exhaust, it could have been just slightly different then yours.

anyway, get some stiffer hangers and see if that helps, make sure you got all 4 hangers back on correctly.

I just switched my exhuast hangers to the sti urethane ones bucause my stromung system over time has worn out my stock ones and it use to swing around to much and hit stuff, it was really annoying auto crossing, having it bang around.

things I noticed with the urethane, a bit more cabin vibration, not much though, hardly noticable, and now the exhaust is rock solid, and they even pulled it up closer to the bumper now

what you might try is, loosening everything up, (cat to midpipe, midipe to axle back) bolts, set the exhaust up, then tighten everything down tight in small incriments. Thats always a good tip when doing exhausts, to makes sure you get them lined up and they stay lined up.

and then again it could just be bad cause its canadian j/k

Jay McDade
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Old 07-13-2002, 04:40 PM   #6
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where are there FOUR hangers? Theres 2 on the can, one on the piping off the can.....thats 3. Is there one on the mid-pipe? I didnt notice it....

yeah, I'm gonna try to loosen it all up and tighten it all down again. Plus the urethane hangers...those might be a good idea too.

Or maybe I'll just move to the US, and everything will fix itself

BLAME CANADA!
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Old 07-13-2002, 06:12 PM   #7
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there is one on the midpipe good sir, should be about 3/4 of the way back from the cat

Jay
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Old 07-14-2002, 11:30 AM   #8
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Yup. Get the poly hangers. Mine moved around, especially under
decelleration. Even just the two rears will make a big difference.
The third one is on the front (axle) side and the fourth is on the
did-pipe, like Jay said. I got the Ion ones.

Installation procedure - equal parts silicone spray and four letter words.
They are stiff and don't generally give enough to stretch into position.
The two rear ones are ok, the third on the muffler is do-able but I
had to detach the mid-pipe form the cat and the muffler section and
"roll" it into position. It was a beotch to get on.

Upside, no more rattlling or buzzing. Downside, the tips aren't centered
too well, and they are ever so slightly touching the bumper skin. It
doesn't look like it is melting the skin so I'm not worried about it.
There isn't much adjustability side to side with them si I'll have to
live with it.

Stu
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Old 07-14-2002, 01:15 PM   #9
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Why? are the Ion ones shorter than the stock ones or something (hence making the muffler closer to the bumper)?


I'm ordering them anyway
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Old 07-14-2002, 01:32 PM   #10
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Quote:
Originally posted by GooseMan
Why? are the Ion ones shorter than the stock ones or something (hence making the muffler closer to the bumper)?


I'm ordering them anyway
I think that they are thicker and don't allow for much (any) lateral
adjustment. Vertically they are right its side to side. I don't know if
you can trim them a little thinner w/o making them weaker.

S.
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Old 07-14-2002, 02:58 PM   #11
GooseMan
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Hrm..well, I'll see em when I get em, I guess

Man, I just looked under my car again.....the piping is REALLY rubbing the CV joint..to the point where its wearing away the paint!

Its weird, I cant even push the muffler to the side with my hands...its as if the whole design was wrong! ARGH! So aggravating.....hope I can drive around like this for another week.....
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Old 07-14-2002, 03:32 PM   #12
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Rubbing = Bad!, just take the thing off, before you rub a hole in it.

Its good that the hangers are shorter, it will pull the exhaust up away from the axle.

I have the STi hangers, not as stiff as the kartboy but they do their job, install was cake, slipped them all on no problems, but I do have a lift to use to my advantage.

Jay
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Old 07-14-2002, 03:33 PM   #13
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oh, call brullen and start bitching! I would.
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Old 07-14-2002, 03:40 PM   #14
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Why call Brullen?

1. He bought it used

2. It has been modified to fit a custom (other than Brullens in this cae) midpipe

I think he should ge ahold of the guy that did the modifying of the can.

RawCode
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Old 07-14-2002, 04:14 PM   #15
GooseMan
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it was in fact modified by Brullen. But the thing is, the whole thing DID fit perfectly when installed! No rubbing or anything.

But then it just moved or something....I dunno

AND, I sold my original exhuast already, so I cant just take this one off

GRRR...hopefully, buy Thursday, I can take it in for a look.

If I cant fix the part where it rubs, maybe I can beat a little dent or dimple into the piping to cleat the axle.
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Old 07-15-2002, 10:01 AM   #16
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Talking THANK YOU GOD!

Whew! Thank the LORD that the best muffler shop in town is open until 7pm during the week! WHEW! Got an appointment tonite after work....hope it all works out well. I cant drive around like this much longer..
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Old 07-15-2002, 10:42 AM   #17
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In addition to the stiffer hangers, also get some small diameter hose clamps. Take the hose clamps and put them on each end of the hanger. It will keep the muffler from sliding around. I had that same problem with my borla, it would walk around because although the hangers were OK, but it would slide underneath from the vibration.

Anyway, give this a try, I think it'll work.

Good luck sir!
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Old 07-15-2002, 10:52 AM   #18
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Here's a pic I drew on paint...let me see if it comes out...
Attached Images
File Type: gif hoseclamps.gif (2.9 KB, 297 views)
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Old 07-15-2002, 06:10 PM   #19
GooseMan
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OH SH|T!!!

I just got back from the muffler shop....the piping rubbed on the CV joint seal! So now the seal/boot is busted, and spewing grease all over the place!

The muffler shop said them may have to fabricate a new peice of piping that'll clear the axle..but they can only do it on a weekend or something....

so we just jammed a rubber bushing on top of the mid-pipe to move everything down a bit....temporary fix, at best

Last edited by GooseMan; 07-15-2002 at 06:26 PM.
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Old 07-16-2002, 01:24 PM   #20
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if you can and have the means, I have a 3" Brullen system, and what I did to clear the CV joint was purchase STI hardened exhaust hangers( you could get kartboy, etc.) and also used a rubber mallet to gently dent the part that did not clear the joint It was a few millimeters dented, not a big deal. Since you have a 2.5" system, the hardened exhaust hangers could solve your problem.I had the same exact problem with the install, everything was fine, till I put the car down. It's because the suspension was uncompressed therefore, the rear axle was lower than what it would be if it were taking the weight of the car. Not to mention, when the suspension settles, it'll sink further down. I was immediately rubbing the CV joint and fixed the problem. good luck
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Old 07-16-2002, 01:43 PM   #21
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Hrm..interesting.....

I made an appointment with a shop that deals with race cars etc... so we're gonna try to figure something out on Thursday..but I DO have the hardened mounts on order. Thanks!
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