DTH Center Exhaust Broken Weld

[gryphon]

I have a Doug Thorley single exhaust with about 4000 miles on it and it is exhibiting a cracking weld at the INLET side of the muffler. This system was from the first batch of D.T.'s production run. I have not contacted D.T. about this problem as I have modified the exhaust side to get a proper exit after I installed a KuhlFx rear valence. I believe that my modification of the system voids the warranty and that the responsibility is solely mine. In any case, I intend to switch to a dual-tipped center exhaust as soon as I find something that I believe will be mechanically reliable and quieter than the current single D.T. This information and image is posted just for information purposes.

[Kermit]

Originally Posted by SteveKen

Although, this thread has been fairly quiet for a few months, I'm not sure if there have been any other issues except for what happened to my standard exit DTH today.

Could this be the first standard exhaust failure, since all others listed here were center exhausts?

The details:

I bought the system used form Russ Barnes with less than 1k on it.
I've since put around 10k on the exhaust within the last 6 months.

Here's a picture of the failure on the driver's side:

I'll post more pics when the system is removed if anyone is interested??

Since I'm probably not going to be under warranty, I'm going to have to try and examine/compare my stock exhaust to see if a SS flex joint can be put in the DTH exhaust anywhere in addition to the repair and maybe also try some modifications.

Even though I'm the 2nd owner, if it were my company, I would replace the exhaust since there's a design flaw that's a non-isolated issue. Anyway, I'm not going to cry about it, since the DTH terms and conditions do state the warranty is non-transferable. Although rules are rules, reputation is everything, correct?

Just wondering if I'm the only one with the failed standard exit exhaust out there????

I've got a home brewed exhaust and I've broke it twice in 20,000 miles. Both breaks in essentially the same spots as the ones listed here (2 different spots). We've since done a refitting with additional brackets. Both breaks were done after extensive high speed driving too. I'll find out if it'll break when I go on another trip in May.

The DT isn't a bad designed, just needs improved upon which they should have it right on target now.

[mendo]

The Motor moves around ALOT!!

I got one of these and it makes it much more stable.
I think it may help prevent some of these failures as well.

http://www.smartcarofamerica.com/gal...mageuser=12856


I got it from MJM in Auburn CA.

here is a link:

Smart Car Muffler

[toestor]

Hello Smarties,

I have owned a Doug Thorley catback exhaust since August 2008 (just a few weeks after I got my smart) and I have been quite happy with it. Then, last Sunday on my drive home on the Highway, as I passed over a lateral seam in the road, I heard a pop and then noise, as if there was a hole in the muffler. (It has only about 10k miles on it.)

Once I got off the Highway I checked and the weld on one of the two braces holding the exhaust had snapped off and pulled a hole into the exhaust. Fortunately the rubber mount held the brace in place.

So: I called Doug Thorley on Monday and after a quick conversation with a live person I e-mailed that person photos of the damage to get their input and hopefully arrange a replacement. On Tuesday I had not heard back, so I called and spoke to someone else to find out that the first rep I spoke to was out for the rest of the day. This morning I called again, but this time the phone was not answered, so I sent another e-mail following up. No response still.

Working in the service industry myself I would expect a response to my e-mail within 24 hours or at least a "we're working on it, sorry for the delay" call. Is that an unreasonable expectation?

Has any of you had experience with a warranty claim with Doug Thorley before? Any suggestions, comments, ideas would be most welcome.

Bummin', t

P.S.: I did buy the exhaust at 4smartcar.com and sent all the documentation to Doug Thorley with the photos of the failure.

P.S.S.: One more question: Do you guys think I should try to "upgrade" (pay the cost difference for one of these: http://www.4smartcar.com/servlet/the...-*QUIET/Detail )? The brackets instill much more confidence ...

[GiantKiller]

Originally Posted by toestor

Hello Smarties,

I have owned a Doug Thorley catback exhaust since August 2008 (just a few weeks after I got my smart) and I have been quite happy with it. Then, last Sunday on my drive home on the Highway, as I passed over a lateral seam in the road, I heard a pop and then noise, as if there was a hole in the muffler. (It has only about 10k miles on it.)

Once I got off the Highway I checked and the weld on one of the two braces holding the exhaust had snapped off and pulled a hole into the exhaust. Fortunately the rubber mount held the brace in place.

So: I called Doug Thorley on Monday and after a quick conversation with a live person I e-mailed that person photos of the damage to get their input and hopefully arrange a replacement. On Tuesday I had not heard back, so I called and spoke to someone else to find out that the first rep I spoke to was out for the rest of the day. This morning I called again, but this time the phone was not answered, so I sent another e-mail following up. No response still.

Working in the service industry myself I would expect a response to my e-mail within 24 hours or at least a "we're working on it, sorry for the delay" call. Is that an unreasonable expectation?

Has any of you had experience with a warranty claim with Doug Thorley before? Any suggestions, comments, ideas would be most welcome.

Bummin', t

P.S.: I did buy the exhaust at 4smartcar.com and sent all the documentation to Doug Thorley with the photos of the failure.

P.S.S.: One more question: Do you guys think I should try to "upgrade" (pay the cost difference for one of these: Smart Car Exhaust *QUIET SYSTEM* Center Dual Tip,DTH )? The brackets instill much more confidence ...

If you have any luck getting even a response back from DT let us know. I've been trying since early last summer. Still no response.

[Doug Thorley Headers]

We are currently trying to come to a solution or retrofit for the damaged systems. The "quiet" system incorporates a much stronger design as well as a ball and socket type connection at the muffler. This pivot ball allows movement in all directions. We will be in touch with all who have damaged systems as soon as a solution is made.

Thanks

[toestor]

Originally Posted by GiantKiller

If you have any luck getting even a response back from DT let us know. I've been trying since early last summer. Still no response.

Wow, I actually got a hold of another sales rep just now (at Doug Thorley) and he told me that they are working on a resolution, but when asked when they anticipate coming to one he would not tell me, but rather indicated they would contact me when they did (come up with a resolution). Felt like he was blowing me off as best he could, and your comment seems to confirm that. Is there an initiative for a class action law suit? How many people do we have who were/are affected by these failures? Any "success stories" of getting a replacement or money back? Thanks, t

[toestor]

Originally Posted by Doug Thorley Headers

We are currently trying to come to a solution or retrofit for the damaged systems. The "quiet" system incorporates a much stronger design as well as a ball and socket type connection at the muffler. This pivot ball allows movement in all directions. We will be in touch with all who have damaged systems as soon as a solution is made.

Thanks

Okay, Thanks, that does sound better. I am perfectly willing to pay the delta between the improved system and my original purchase (plus shipping). In researching this further I have found that other manufacturers are also going to a flexible connection at the cat end. Does your new "quiet system" do that as well? I noticed the strengthened attachment points. Thanks, t

[VinceLA]

toestor, yes a bunch of us received our replacements last year, I believe. Since 4smartcar.com is local, when I did was walked in with the damaged piece and they gave me the 2.0 version. Others might have sent theirs in.

For the time being, what I would do is remove that broken brace from the exhaust holder. Find a small piece of metal sheet/plate and 2 clamps. Bend the plate to 'cover' the hole and clamped the plate down. It should reduce the exhaust leak to some extent. That's what I did back then and it worked fine.

[toestor]

Thank you Vince, I am in Colorado, so I will have to deal with some delay due to shipping. I did remove the the broken piece from the holder. The sheetmetal/clamp idea for a temp fix sounds good. I will go to the hardware store right now and see what they have in the plumbing section . Thanks, t