Hunting For a DIY Exhaust Solution
 

Ok, unfortunately the title doesn't really describe what I am looking to do, so hopefully this picture does:

https://sphotos-a.xx.fbcdn.net/hphot...78430631_o.jpg

As you can see, I have had a TXS exhaust installed on a S2.

https://lh3.googleusercontent.com/-K...923_130414.jpg

Here is where the problem lies. The intermediate pipe hangs just low enough to cause sporatic clearance issues on major deviations in road grade. Luckily I have not damaged the pipe at all, but if you look close enough, you can see the scraping is happening to the exhaust hanger.

https://lh5.googleusercontent.com/-Z...923_130349.jpg

Here is a better view of the hanger

So here is my question.

1. The "easy" solution is to say "ok shorten the hanger on the intermediate pipe". This is fine, except that causes the rest of the system to hang higher, which in turn will not work as I will be limited by the exhaust shrouds.

2. Have an exhaust shop chop cut the intermediate pipe and the flange, and build a section that angles to the muffler section better. Now that is the "best" option, but of course I run into 2 issues. One issue is that exhaust shops in the area wont touch the car cause I dont have a cat, so I would need to get my lazy ass on the ground and replace the oem cat. The second is that it would cost anywhere from 100-200 dollars, which annoys me because at that cost I could have just invested in a better fitting exhaust system.

3. A friend mentioned chopping the intermediate pipe to muffler flange, and using a flex pipe section that will allow me to raise the intermediate pipe without moving the muffler section. The only concern here is quality, and the reliability when dealing with the high EGT of a rotary.

Anyone else got a solution that they can think up. I prefer a DIY solution so that I can keep cost low.

Cut the TP hanger and add to the rear hangers?

wish I could, but barring any chopping of the flange, i need to retain the mating angle (you can see the muffler flange angles downward)

Another solution i was thinking of is bending the tips down a bit so that I can raise the entire assembly up without hitting the shrouds ..... question is, how can i do that without fracturing the pipe

I never noticed the gap difference in shroud clearance from left to right too. You're welcome to come down to the shop and put it up on the lift.

It may be possible to cut the flanges off, stand up the exhaust for proper angle and height and then reweld the flanges in a new position. I got a mig wilder. And we could bend/cut/torch/rework...the hangers to fit properly.

Yea that gap is just enough to get on my nerves lolol. I appreciate the offer and may take you up on it. We can discuss more on Sunday if that is ok with you. I am looking to pay around $100 max for the work so let me know if that wont cut your fees.

I would start with bending hangers and trying to get it to fit better first and then see if invasive hacks are needed.

This is hard to do without kinking or cracking the pipe. Easiest fix would be to cut the pipes with tips at the muffler and then weld on at desired angle.

Yesser.

I have a very similar problem with my TXS catback / BHR midpipe on my S1. I've ground down a portion of the hanger where it attaches to the mid pipe... not too bad but there nonetheless.

^ completely missed your post SD. Yea i never thought much of it because i thought I would eventually wear down the hanger until it cleared any obstructions, but I am getting worried that i will soon start chewing through the intermediate pipe.

part of me just wants to go down there and chop off the flange, raise the intermediate pipe, and throw on a flex pipe with the vband clamps from jegs