Got my midpipe installed and it sounds really weird... Like I left a ratchet on something somewhere and its spinning...

^ mine sounds exactly what you described. Theres a spinning noise after i let off throttle. I jsut got back from the shop and it has no leaks. So i dont know what else it could be.

IIRC, back when the midpipes were coming out one of the rattle issues was due to the hanger support (that goes into the rubber OEM mount that supports the cat) off the pipe rubbing against a frame member of the car. Even it the hanger isn't touching any part of the car when you have it installed, if it's close enough it will rattle against it with the car vibrating from engine idle, acclerating or just flexing going over the road.

I bent the hanger around the member so it would never touch when I first installed the midpipe and never had any rattles from day 1. Just winging it from my personal preference, if it's 1/8" or closer to any member underneath the car I would make a larger gap. Try pushing the midpipe around once installed to see how close you can get the hanger to move to the closest nearby part to check the clearance.

how did you bend the hanger ??

Im sort of disappointed by the shop. You can fully hear a rattle at idle and he checked for leaks but didnt further investigate what else it could be.

Im with you on this one... Still trying to find my rattle when my car works... Waiting further diagnosis until I get my new engine in, then Ill try to find my rattle (Although Ive looked for it before, and it couldn't be found).

Just old school way, get some leverage and a solid object to help out, bend it with a combination of your hands and the closed loop end of a wrench

I used the breaker bar while underneath the car, wedged it between the frame and the hangar to move it up with my free hand and when I needed to go down use the closed loop end of the wrench sliped over it just past the nipple end of the hanger for leverage and bent it.

Can't recall what I used for support to hold the bottom of the hangar up when bending it down but it had to be something solid. Perhaps I managed to wedge the breaker bar underneath it and up into the frame again for support, I can't recall. Make sure you have something solid above or below the hangar depending on which way you're bending it to shape.

IIRC they're using 300ish grade SS and it's TIG welded; you're not going to easily break the weld doing what I did given the high quality effort BHR puts into it. IF you don't have much experience working with metal and are worried about it just go slow and use common sense.

^ I cant really understand how you bent it like in which direction sorry lmao. WOuldnt bending it make the pipe hang lower ??

So is this a donut gasket issue or a hanger issue ? Before i order the donut gasket id like to know lol

First off, for my shape I bent it both ways. If you only bend it one way it's going to be angled away from the rubber mount which you don't want. The idea is to bend it almost to give a slight U shape in it to clear any part of the car that it's close to.

Secondly, you will have to install the midpipe again to check the clearance to know whether or not it could possibly be the hanger. If you're confident it's not the issue then you eliminated that possibility. If you're not sure you could always post a picture to get a general consensus.

If I were you I'd check the hanger first before spending your money when it may not be the issue. While you're at it, look closely all around to make sure nothing else is close enough to be a cause

Will do thanks !!!

Youre saying the engines front rotor low compression that i know i have is causing the rattle ??

im not attack your product at all. I know the quality of your products as ive said before. I bought your midpipe in hopes it would fix a high end power issue i was having and it obviously didnt so the only answer i can think of is bringing it to mazda for the compression test in hopes of a new engine.

well, I seem to have the exact same problem, did anyone ever find a solution to this? or what did you guys end up doing? or is it just normal?

I have an 09 rx8 gt 6sp

I have about 60k on mine and it occasionally rattles, mostly at idle.
It started a few months ago.

Possibly a broken or corroded tack weld on the metal baffle.
The pipe is SS, but it's possible the weld isn't and corroded.
I'm not too concerned unless it sounds like the whole thing breaks loose.

Charles from BHR no longer posts here and deleted a lot of his helpful posts.
You might try emailing him, Idk if you'll get a response.

I just got it, not trying to doubt the quality of the product, but 3 exhaust shops have told me it sounds like the resonator is messed up. I emailed Charles he's claiming any sounds I have are normal, I sent him some clips of the sounds(kind of hard to hear) but I'm waiting for a reply now.

most of the noise sounds like rasp or sand in a blender (it's not that, I already have the part installed for that issue) and only happens when I apply a decent ammount of throttle(any rpm, same exact noise) sort of sounds like an exhaust leak but i really don't know. The shops I took it to told me no leaks so i really have no clue haha

https://youtu.be/pFbUelpc_I8
https://youtu.be/BFtoH78gxRg
https://youtu.be/Ivc5zqlc60M
https://youtu.be/NSVcItvNu0c
https://youtu.be/xc9jgkPJGVw
https://youtu.be/lRoCjHvn-7Q

My car started rattling after installing my midpipe too. Sounds just like everyone else's.

Stock R3:

After BHR Midpipe:

After hanger was "fixed":

My rattle is coming directly from under the middle of the car, sounds like it's from just behind the resonator, I gave hp trying to figure it out and now live a happy life forgetting that rattle ever existed

10 years later, same issues. BHR is not what i imagined..
 

Bought a BHR midpipe thinking it would be the best 600 bucks i could put into my car.. what a disappointment. "great customer" support blah blah blah.. i feel betrayed. i can hear the guys anger and passive aggressive tone through the emails.. im ready to throw this midpipe in the trash. anyone who wants it, its free. Montclair, CA. if anyone has a RB midpipe im willing to trade.

When did you buy the midpipe?

Have you reached out to BHR with your concerns?

Travis

I bought a midpipe, coil kit , clutch bracket and fuel ring tool from Ray and never had a problem.

This is one of only a few instances I've seen of someone unhappy with his customer service.

If there's a problem that can be fixed within reason he usually takes care of it.

At least he has in the past, Idk about recent history.

*I recently bought a used BHR catted midpipe to replace my regular resonated one, no issues with it either.

I've purchased a few products from BHR and know many who have as well.

He has always stood behind his product and fixed/helped troubleshoot any issues that have ever shown to my knowledge, which is why i would very much like to see the emails exchanged and get more information.

Travis

Just to update, after driving my LY with a new engine after it was sitting for 3 years I didn't notice a rattle.

I replaced it with a catted pipe just so I wouldn't have to swap out for inspection anymore.

He has blamed everything from engine age, to ignition, to injectors for the noise.
the first few days after I installed it it was perfectly quiet (car is stock besides TEIN springs). If any of those things were the cause then it would have made noise on day one. When I proposed that it might be heat cycles causing expansion or movement within the resonator that is causing a rattle, he replied saying it’s impossible for his product to fail.
sounds a bit delusional to me. I’ve never heard of a manufacturer with 100% success rate. I wasn’t trying to bash a reputable company’s product. When I reached out I was expecting something like, “no worries we’ll take care of you” or some kind of help.
he asked me to remove the midpipe and tap it on the floor while holding it up from the hanger. How am I supposed to match the pulses and frequencies of a rotary engine? The test made little sense. I’ve had the car on a lift at work multiple times and I can tell you the noise is coming from inside the resonator.

Well, given he is the one who created it, even if the test doesn't make sense to you, shouldn't you perform it anyway?

Charles knowledge of this platform is difficult to match and he has shown throughout the years to be extremely helpful with his customer base, which is why so many regard his customer service as second to none.

When using a midpipe, instead of a full CAT, you are going to experience more noise than prior to.

But, in your own words you told him you would complete the test. So, what were the results of said test and what was his response after you reached back out?

Travis

I did perform the test and the rattle I hear when the car is running was not present.. I did not reach out after that since I already know what response I’ll get. At this point I just feel like I paid 600 to make my car sound like it has a massive exhaust leak..
Going to put it up for trade for an RB, and if nobody takes a trade within a few weeks I’m just going to give it away, and if nobody picks it up then it’s going in the trash after that.
when you buy “the best” and most expensive midpipe you expect to get what you paid for in quality and customer service. While the part looks well made externally I can’t be sure about the internals.
after seeing the responses that not only I have received but other in this forum, it’s clear to me that BHR believes they can do no wrong.
To me it’s like getting food that’s gone bad at a restaurant and the waitress tells you that something is wrong with your tongue..

To me, it seems as if you have not fulfilled your side of the agreement. You simply made an assumption and chose to give up, instead of reaching back out.

I assume it rang when tested instead of rattling.

But again, you made an assumption and chose not to fulfill your end of an agreement you made. Perhaps if you had, further assistance would have been provided.

But, that's how I see it.

Travis

I told him I would keep him posted before I saw his completely unreasonable reply. He’s saying there’s no way the part could ever be to blame unless it was one of the first 5 ever made. That’s telling me that no matter what evidence I show is pointless. He can just tell me it’s not the parts fault. I understand that he has a large and loyal following on this forum, and it’s starting to look like an “either you are with us or against us” situation. Many users here have run into the same noise complaint, but the threads seem to just dry up and everyone just moves along without considering maybe there really is a problem with some mid pipes.