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Old 04-27-2003, 11:20 PM   #1
bahboy20
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Default exhaust install problems

Hey guys, XenonK was a beast and installed a Apexi N1 catback from a 2001 2.5 RS onto my 2002 2.5 RS, but we hit come problems.

1) At the connection between the cat and the midpipe, there is a problem:
Ideally the connection would be like this- the cat flange presses right up flat against the midpipe flange, with a gasket between the two flanges to make a good seal.

However, as you can see in the image, the flanges are not flat. There is a piece in the middle that I dont know what it is. Is it part of the cat or a removable piece? I thought it was part of the cat that would need to be cut...anyone know?

***IMAGE***

On the stock exhaust, the flange on the mipipe had a little recess to accept the portion of the cat that is extending, so that the flanges would end up being flush and no possible leaks.

However, as you can see, the Apexi midpipe doesnt have a little recess to accept the cat portion that is extending through the cat flange, and therefore the flanges and the gasket in between are not flush. Right now there is not a leak, but because the flanges are not flush like they should be, I dont think this is a good idea?

Anyone have any experience or suggestiosn on this? One suggestion was to just cut off the portion of the cat that is extending through the flange, so that the flanges can now butt against each other.

Also, those little springs on the cat side to hold the exhaust have no room to be installed now, and are not on the car. Is this bad?


Please, I need some help here.


thanks,


Dan
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Last edited by bahboy20; 04-28-2003 at 06:21 PM.
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Old 04-27-2003, 11:23 PM   #2
watcher in the sky
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hmm i had an apex n1 cat back at one time.. mine was recessed for the donut washer type thing. Hate to sound simple, but, have you got the midpipe turned around the wrong way?

Justin

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Old 04-27-2003, 11:38 PM   #3
bahboy20
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Default hmmm

Watcherinthesky:

Thanks for the reply.
Well i am not sure about the pipe orientation, since XenonK did the install, tho i was watching.
However, would it even be possible to install the midpipe facing the wrong way? All the hangars lineup fine now, if it was installed reverse, wouldnt the hangars not match up?

There is like 1/4" of the cat that mushroms/extends through the cat flange. So that means that there would have to be a recess of 1/4" on the midpipe flange, to accept that cat portion to enable the flanges to lie flat on each other...do you recall that?

When your exhaust was installed, were the flanges at the interface between the cat and midpipe totally flat (ie the flanges were flat against each other) or were you able to see part of the cat between the 2 flanges?

ANyone else?

Dan
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Old 04-28-2003, 01:22 AM   #4
watcher in the sky
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mine was exactly like you stated that yours is... so all i can think.. is that the midpipe isnt quite made correctly.. OR, it isnt even an Apex, and is just a custom midpipe, that someone didnt get the flange made correctly. I just installed a stromung midpipe today (coincidence) and yes, at the cat, there is a "donut" that extends from the flange, and on the midpipe flange, it is recessed the proper amount for that donut. My apex was the same way. What's wrong with yours.. i do not know. Sorry i cant be of more help.

Justin
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Old 04-28-2003, 11:58 AM   #5
bahboy20
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Default pics of the problem

Guys, here are some pics to help illustrate the problem.
As you can see from the close up image, the problem with the cat.
As you can see from the other image, it is on my car, but by no means am I content with the cat being like how it is....

Any suggestions/advice?

CAT

Installed

Link if images dont post


Thanks for all the help!

Dan

Last edited by bahboy20; 04-28-2003 at 02:49 PM.
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Old 04-28-2003, 12:57 PM   #6
watcher in the sky
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oh ok.. thats not like mine.. close but not.

Yours = ===|] |=====

Mine = ====|} |====

mine is tapered.. yours is straight.. WHICH is why mine fits. The pre 02 car had the tapered "donut" and the 02+ had a straight peice coming through like extended pipe i suppose.. SO.. the only way it's gonna work i suppose is to weld it.. or just take it to a muffler shop and let em go to work.
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Old 04-28-2003, 02:47 PM   #7
bahboy20
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Default muffler shop?

Is there any problem with leaving the joint like **THIS** ?
Is the potential for a exhaust leaker greater?

Should I have that part of the cat just cutt off by an muffler shop? Does that pose any problems down the road?

Dan
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Old 04-28-2003, 03:01 PM   #8
Mirage
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Pry that donut off with a chizel and a hammer if a screwdriver doesn't work, it is a separate piece that is fused on from all the heat since it was put on. I ran into the same problem and made my head look like this guy's .
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Old 04-28-2003, 03:45 PM   #9
bahboy20
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Default are you sure?

Are you sure that the piece extending through, in my attached link attached, is the SAME part you chiseled out? Are you sure you just didnt remove an O-ring or something, because sometimes when you install a catback, you have to replace the O-ring or gasket, since it might be pretty beat up...

The part I am actually talking about is labeled 'cat to be cut' in the link below. I woudl say its about 1/4" to 1/2" thick,and its not an O-ring or gasket, which would be real trivial to remove.

Are you sure you chiseled that out and not an O-ring or some type of gasket?

***LINK***

If it was a separate piece, would it have been hard to remove the midpipe?

When you say fused on, do you mean that it has some type of adhesive or something? If its a separte piece, how is it held on, and would it even be possible to remove it without some machine?

DId you actually have to pry it off your car for the install? Was it about 1/4-1/2" thick, and not an O-ring or something?

Dan
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Old 04-28-2003, 06:01 PM   #10
JohnP555
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While I am not exactly sure if this will answer your question, I will go ahead and attempt it anyway:

I have an Apexi N1 catback system on my 99 RS. I would assume the orientation is the same on the 2002.

That little donut flange needs to be removed. Break it off with a screwdriver and hammer, chizzle, or something. It has to come off or else it is going to fit like you have it in the picture. I don't know if it is a problem, might cause exhaust leaks, but you should take care of it.

You think yours was hard to remove....my car was 3 years old when i did the exhaust. That donut was fused on there and took serious force to get off. Once it is off you can fit the mid pipe right up to the cat with no problem. Just get a new flange to put between the mid and cat after that donut thinger is gone to prevent further leaks.
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Old 04-29-2003, 12:05 AM   #11
watcher in the sky
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Quote:
Originally posted by JohnP555


That little donut flange needs to be removed. Break it off with a screwdriver and hammer, chizzle, or something. It has to come off or else it is going to fit like you have it in the picture. I don't know if it is a problem, might cause exhaust leaks, but you should take care of it.

why did you have to do this on your car though?? that donut shouldnt be removed. .. BECAUSE the apex midpipe is recessed the right way for a pre 02 rs!!! the newer ones have a straight peice that comes out .. instead of a "slanted" (for lack of better word) one like on the older rs's.. i know this to be DEFINATELY true on my 00 rs, because i've been under there 4 times.. and just put a stromung mid on there Sunday.
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Old 04-29-2003, 12:27 AM   #12
bahboy20
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Default hmm

hey watcher in the sky--
i think that maybe you guys are talking about different things.

a couple people have told me that have removed that portion-- are you sure you didnt have to remove anything for your install?

at the least, you must have removed the stock gaskets, right? maybe when you removed that the piece came off with it?

or maybe for some reason there is a difference in the cats between your car year and the years of the otehr people who said they removed that portion?

this is quite baffling, but i am sure there is a good explanation to this all.

you mentioned the midpipe (apexi) having a recess to accept the portion...well the portion that extends is like 1/2". that would be a really big recess to have in the midpipe...or maybe my car is different? I dont know.

Dan
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Old 04-29-2003, 01:22 AM   #13
watcher in the sky
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letsee.. how to put this...

the donut on my car.. is rounded.. i DO NOT have that extended straight peice like you do.. never have. The flange on the cat has the donut on the inside portion extending about 3/4 inch out... the flange on the midpipe is has a recessed area for the donut. THe apex did, and so did the Stromung i just put on Sunday. I dont know anyother thing to say.. that's just how mine is. Hope you figure it out.. sounds strange to me.
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