Well, after I put together the clutch and align the Power Frame, and thought it would fix the exhaust mis-alignment (I had the clutch replaced by a shop before and they did not do a good job and the PF was mis-aligned and the exhaust bolts were over tighten, etc). In any case, the exhaust mid pipe is touching the heat shields right after the Cat. So i don't think it's safe to drive like that. I've also re-align the PF several time with different configuration, but it's still touching the heat shield.

The only possible thing could happen is the exhaust must of bottom out and hit the ground and cause the pipe to bend as there are scratches on the bottom of the Cat, but I don't recall if I ever hit anything like that.

I just want to know if there is any other possibility which I might over look that may cause the exhaust to misalign? Can the header cause the exhaust to misalign if not installed properly? I had remove the header before, but I don't recall the exhaust touching anything when I put them together; maybe I forgot to check properly?

If there is no solution, I will have to resort to cutting the pipe and re-weld it which I hate to do and would like to avoid if all possible.

ps: everything is OEM btw

Any ideas?

Thanks,

Hau.

you have a failed motor mount or 2.


beers :beer:

hmmm, Have any pics?

This is the picture of the exhaust looking normal with gaps between header & cat flanges:
http://www.rx8club.com/attachment.php?attachmentid=103003&stc=1&d=1182748829

After tighten the header & cat flange bolts, this is how the exhaust look like. Notice the circle section is touching the heat shield:
http://www.rx8club.com/attachment.php?attachmentid=103004&stc=1&d=1182748829

And the mid pipe was also touching the head shield:
http://www.rx8club.com/attachment.php?attachmentid=103005&stc=1&d=1182748829

Regarding the engine mount, it might be it. I can't really tell if the mounts are bad:
http://www.rx8club.com/attachment.php?attachmentid=103006&stc=1&d=1182748829

From a different angle, does this mount look normal?
http://www.rx8club.com/attachment.php?attachmentid=103007&stc=1&d=1182748829

Look like the mount is bottom out and touching the frame? What's the gap size between the mount bottom and the frame? do I need new motor mounts?

As a temporarily solution, I end up installing the PF with about 1" off from it normal spec to get the exhaust mid-pipe not touching the heat shield. Between the lowest point of the PF and the high point from the cross member, I got about .5" gap. Not much to spare if I ever hit a bump; the frame may come in contact with the cross member piece.

I need a drink :beer05: