DTH Center Exhaust Broken Weld

[jonnysan]

Originally Posted by WilyB

There must be a reason why the factory exhaust comes with a flexible coupling: vibration damping.

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And a good reason why braces are not welded to any weak, thin wall part of an assembly, too..... Coefficients of expansion and weld bead perifery crystalization at work, too. Not a metalurgist but I have decades of experience with welding practices/materials, etc. so I can make these statements with some confidence. Upgrade of the part is needed, that's all. Simply a learning experience not meaning to be too critical....

John

[SMART]

Thats too bad to hear. Please let us know how it develops.

[BlkonBlk]

Same thing just happened to me 2 days ago!!!! i was so pissed emailed 4smartcar.com and elie took care of it only have 2000 miles on my car and hes sending me out a new one ASAP, also thinking about putting the old one back on..does anyone have any idea if maybe this could hurt the manifold...im worried about somthing more eh ehm exspensive breaking from the stress...

[p1nball]

Has anyone with the original single DTH have any problems? Just checked mine and could not find any cracks or signs of Stress. Lets hope it is just a random few that has this problem. Makes you think that the flex pipe might be the proper way to exit the manifold. The only place the muffler gets to vibrate is in the rubber dougnut, that are attached to the muffler supports. With motor moving around and not much play, could brake or crack the manifold or the bolting flange!!

[jwight]

I don't have the links but apparently there was some earlier concern about this in the UK on an EU manufactured exhaust - again, no flexible coupling at the manifold. Maybe someone can supply the details. Anyway, after this was pointed out I opted not to fit an aftermarket exhaust.

[EdwardDennis]

Originally Posted by p1nball

Has anyone with the original single DTH have any problems? Just checked mine and could not find any cracks or signs of Stress. Lets hope it is just a random few that has this problem. Makes you think that the flex pipe might be the proper way to exit the manifold. The only place the muffler gets to vibrate is in the rubber dougnut, that are attached to the muffler supports. With motor moving around and not much play, could brake or crack the manifold or the bolting flange!!

My DTH single is still looking good. I do have my factory exhaust, however, wrapped up and stored--ready to be bolted on at a moment's notice.

Personally, I'll take a cash refund if I have a weld break--unless they can demonstrate that their replacement unit exceeds their original specs.

[tigerwong58]

I agree, Elie just gave me the tracking number to my replacement unit. I also hope this is random and it will not happen again. As a precaution I will use a stainless steel muffler clamps on the bracket/bars where the attach to the pipe, this should make it stronger.

[donnyonee]

sorry but you just spent how much and now your going to fix it with a hose clamp?
i also have a dt muffler, great...

[VinceLA]

Originally Posted by tigerwong58

I agree, Elie just gave me the tracking number to my replacement unit. I also hope this is random and it will not happen again. As a precaution I will use a stainless steel muffler clamps on the bracket/bars where the attach to the pipe, this should make it stronger.

So think about this. The DTH exhaust is a solid piece from the header right down to the tips. Held by 2 bolts on the header flange and 2 hangers dampened by the rubber holders. Vibrational forces are transmitted from the engine (top) and from the hangers (bottom). Assuming the forces from the bottom are less than from the top given the rubber holders. We can't deter forces from transmitting from the top without drastic modification. But maybe something can be done to change the hardness of the rubber pieces.

My further guess on this matter is that the rubber holders are way too hard for an exhaust system without the flex coupling.

[chieftmc]

Originally Posted by VinceLA

.....My further guess on this matter is that the rubber holders are way too hard for an exhaust system without the flex coupling.

AND will eventually break / crack the manifold