My buddies '06 JCW broke the front hangar off, right behind the cat - he's out of warranty by about a month, but the dealer is replacing it under warranty......

 

My Volt exhaust resonator recently blew itself apart, found out the thing was rusting up and was rattling like crazy around 2k RPM's.

After it disconnected itself, I went and upgraded my header and cat to the RMW brand that Jan sells (love it!), and spent $70 to have a new mid-pipe welded in, sans resonator. The tone is much better, even though it's SLIGHTLY louder.

 

My header broke in half.

 

As an option for using the same part for replacement use part of the system from an R53.

In the R53's the resonator is in the back. So, just find a used system, cut the front section off and bolt it up to the flange. Then attach the JCW system to the back of that with a MINI clamp.
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As far as I know, no issues have been reported about anyone's R53 system splitting there....so it would be a more "permanent" fix.

 

96,000 miles and my exhaust header cracked...Schomp Said is was on a weld and could probabally get it fix...then 2 days later my car got LOUD.. LOUD!!

not really able to spend the $1750 to have schomp replace it.

-Illminiyou