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James
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1,094 Posts
Discussion Starter #1
Today I re-built my exhaust system. I have a 2007 K24 Sedan.

First off I had to solve the broken flex pipe problem on my header. So I cut out the old crappy one.



You can see around the edges how the flex pipe had started to fray and split. My theory is that it is a piece of garbage from the factory and it simply cannot handle the heat and pressure generated by the engine so it split from the inside out.

In its place I welded in this piece. It is a stainless steel flex bellow.



Had to cut about an inch off of one side and half an inch off the other but other than that it fit perfect on the header and welded in no problem.

Once I solved that, I turned the car on and and it sounded BEAUTIFUL. No more hissing header noise, no more power robbing air leak.

The next step was cutting out the old Skunk2 muffler.



And replacing it with the Vibrant Performance Stealth Muffler.



It ended up being quite a difference. To eliminate even the littlest amount of leftover drone, I welded in an 18 inch Vibrant Performance Bottle Resonator. At this point my hands were filthy so I stopped snapping pictures. So I have none of that documented. At the very bottom of this next picture, you can see the resonator standing up on the ground.



It welded in right under the passenger seat area.

While I had the car up, I threw in a Cusco Underbody Brace.





We got it installed in about 45 seconds, it attaches to two subframe bolts and 4 frame rail bolts. Great addition to the underbody, it looks nice but I can't say I really feel much of a difference. I was mainly doing it to protect the newly customized flex pipe anyway.

I also adjusted my rear camber a little.



Sorry it came out so dark, but you can just make out the blue Megan Racing arms near the top of the picture. The green bar is my TL-Type S rear sway... I painted it that color because it looks pretty neat under the car. I have a VP model so I never even had end links for it to attach to.... you can imagine how much better the car felt after that!

Anyway, thanks to everyone who contributed advice, knowledge and suggestions for the past few weeks in regards to this project. Also thanks to those who sold me all the different parts!
 

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James
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1,094 Posts
Discussion Starter #2
did anyone else do any kind of work like this to their header?
 

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James
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1,094 Posts
Discussion Starter #4
yeah, wish I had done more research before buying it. Oh well, so far so good with the bellow
 

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AdRiaN
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1,049 Posts
Glad u were able to put that bellow to good use :) or else it would have sat on my garage for years lol
 

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Let the good times roll..
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507 Posts
That is sick, never seen a flex that looked like an accordion, wondering if it would fix my hissing noise I have after installing pcds.
 

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James
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1,094 Posts
Discussion Starter #11
Glad u were able to put that bellow to good use :) or else it would have sat on my garage for years lol
Thanks again adrian!

Op are you running pcds?
Running a K24, so no precats

that's a badass flexpipe
thanks! it really is, so solid.

That is sick, never seen a flex that looked like an accordion, wondering if it would fix my hissing noise I have after installing pcds.
Well, my hissing was because my flex pipe was literally shredded. I can now distinctively hear intake and exhaust seperately ... before it was all just one indistinguishable mess
 

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James
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1,094 Posts
Discussion Starter #12
A little update today:

After about two weeks with the new flex bellow, the hissing returned, worse than ever before. I was bummed out pretty bad so today I threw it up on the lift to see what the problem was...

Turns out the welds are as solid as ever and there is absolutely nothing wrong with the flex bellow....

One of the bolts had come out of the DC Sports Header. -_____-

It must have been loose when I installed them a year ago. I slapped in a stainless bolt washer and nut and I'm back to no air leak.

So, I do recommend products such as these in situations like these. I'll update again in about 6 months just to see if any complications develop.
 

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James
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1,094 Posts
Discussion Starter #14
Had some recent developments with the exhaust...

So the flex bellow was a good alternative to a flex pipe, but not as perfect as I originally thought. After some time, the piece started to stick and not contract and expand like it was doing, and was making an awful rattle noise.

My next project will be to replace the bellow with this heavy duty stainless steel flex pipe.



It is much stronger than the original one on the DC Headers. It should eliminate the rattle altogether and hopefully last a long time.

Today I welded in a Vibrant Performance Resonator, which surprisingly reduces exhaust volume ALOT. It is perforated just like a muffler and the sound is trapped in the 360 degree baffling.



When I get the flex pipe in I'll update with some pics.
 
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