DTH Center Exhaust Broken Weld

[Okie Boy]

Originally Posted by WhiteNBlack08

This is not true, most modern systems(especially FWD) have some kind of ball coupling between the manifolds or headers and the exhaust system. While not as flexible as the OE smart setup, it does allow movement and flex in the system.

Those Ball-Flanges intended purpose is for ease of installation and in some cases the clamping force is limiited by springs on the clamp bolts which may allow ball-joints some movement but not much and not in all directions.

The flex joint is used in the smart I suspect because of the mass of the factory exhaust, with 20+ pounds of muffler it would put a lot of stress on the manafold at idle when the engine tends to shake and also at those majic resonate frequences that make things rattle and buzz in the smart. The after market mufflers are very lite, not much mass to move, and I am trusting that DTH has some experience in after-market exhaust design and manufacture.

[tigerwong58]

The welds are good, because it tore off a section of pipe. If the weld was bad the pipe would be ok and the bracket would be the only thing that came loose. It's obvious it was caused due to not enough flex or give at the donuts, or flex in the pipe like the factory muffler. I am going to bring the replacement muffler to a muffler shop and weld an additional stainless steel bar to create a triangle (like the BPP bracket).

[WilyB]

Originally Posted by tigerwong58

I am going to bring the replacement muffler to a muffler shop and weld an additional stainless steel bar to create a triangle (like the BPP bracket).

Sounds like the right thing to do.

Well, let me rephrase that: Sounds what DTH should do before shipping you a new one.

[Doug Thorley Headers]

OK, I am sure everyone has been waiting to hear from us about this. Yes, we have had a few calls on this situation and without getting into too much detail, we feel it is isolated to a certain run of the exhausts. We have already had another Smart Car in our R&D dept. so that we could look into what may be causing the problem. We have made several changes to our system that will resolve any issues that may have contributed to the situation and stand behind our product 100%. I think we all as consumers (yes I buy stuff too ) can get frustrated when things happen but rest assured we want to make it right because I want good parts on my car also. That is why we got a car in as quickly as possible and are not just changing 1 thing in hopes that it will resolve the issue, but changing many things to make it a better system overall. Again, we appologize for any inconvenience, but appreciate your patience and we will let you know as quickly as possible when there are more updates.

[WilyB]

Great response!

[tigerwong58]

DITTO, GREAT RESPONSES ! ! Thanks for all the feedback and ideas.

[Doug Thorley Headers]

Actually, I want to thank everyone for their feedback. If I don't hear about a problem, I cannot fix it. Kind of Pandoras Box, hate to open it, but at the same time the amount of information you can gain is priceless. Thanks again for everyones support and we will keep you updated.

[tigerwong58]

So is the one I am getting as a replacement to new, improved version or the old version. I would hate to have this happen again.

[mrbadexample]

i'll be ordering a DTH side exhaust system soon. glad to see DTH is on top of things. i don't need the dual fart can look, i can live in "stealth" mode (if there is such a thing for smart cars in the US)

[VinceLA]

Originally Posted by Doug Thorley Headers

we feel it is isolated to a certain run of the exhausts.

Thanks for the reply Nick.

I have a 4smartcar.com exhaust as well. Just checked it this morning and it is still ok. I bought mine from another member in mid July. Am certainly one of the very first to install the unit.

Not sure if this is of any help but IIRC, TigerWong and BlkonBlk bought theirs after I did. Perhaps a certain run like you said?

Please keep us posted!