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Good news: over the past couple months I’ve taken time when weather permits to slowly start removing the necessary parts to extract the exhaust manifold. I live in Northeast and broken bolts are always an issue. Everyday I went out to do some work, I sprayed pb blaster on the 8 manifold bolts.
Today we hit the mid 60s and woohoo all 8 came right out.
My dilemma: I’ve got 110k miles and want to keep this job to under $350, last awhile, and not throw codes (keep main cat and O2 sensors). Adding O2 emulators is not an option.
Current status....
R53 poor mans JCW. Cat back is JCW with the resonator removed (I still have it though), 17% pulley, JCW 210 factory tune, JCW 380cc injectors, JCW CAI.
Do I....
A) have a muffler shop re-weld pre-cat
B) have a muffler shop remove pre-cat with pipe
C) Non OEM headers (obx is just near my budget) and have a muffler shop add the oem cat
Lastly: What prep is needed at the exhaust manifold mounting surfaces besides new bolts and gasket?
I had the exact same broken weld. I just marked up the correct positioning before removing the two pieces and had a local exhaust shop weld it back for $25. I re-used my old bolts and exhaust manifold gasket without issue (my old bolts were not too rusty). This was the most cost effective option for me; I may do a header later on but I really like the sound of just my JCW cat back.
+1 for having a local exhaust shop weld mine. I brought him the header to have the cat welded (split on a seam). When he inspected it he found the beginning of a crack in the location yours has broken.
$30 for the fix and then whatever it cost for the gaskets. Cheapest fix I've ever done
So I brought the header to “[redacted] custom exhaust” and had them cut the pre cat and replace with a piece of SS pipe for $106.25 (included tax). They f’d up the threads on the 02 bung so they replaced that for “free” (and sensor come to find out). They also threw in a new set of flange hardware and gasket.
Final thoughts on stock header, pre-cat delete, resonator delete, and JCW SS mufflers. Meh.
Maybe since I haven’t driven it in 3 months I really can’t say if it’s better. For $100, I’m def happy I went that route.
FWIW: There was way more pop and burble with the one-ball mod so I miss that.
Precat delete due to split weld
I had my cat split at the same seam as well and I wish this thread existed before I got on the route I'm on now. I bought a Megan Racing header and installed it, but the ECU is bugging out due to no-CAT. Gonna end up dropping another $500 at least to get a new GESI high-flow cat weld up and replace the cheapo aftermarket oxygen sensors I bought with NTK ones. It'll benefit me in the long run, but it hurts a bit in the interim. Eventually I'll add a resonated Milltek catback but that'll be awhile from now.
Just weld it up! Had this happen a bit before Christmas on ours and I just welded it back together on the car. Car on the lift, pole jack under the exhaust, burn in a fat bead. Not my best work, but very solid and no leaks for the last 3 months.
San Diego - Dual Tone - super honest and reasonable. No hesitation to recommend. ( yes, my sig is east coast, but my r53 is now enjoying SD )
Many thanks! I'm considering replacing it myself but I'm worried for the bolts breaking off and other mishaps. Any idea if the the converter-manifold unit can be wiggled out from the hood side on cooper R50 without moving the engine/transmission?
So I brought the header to “[redacted] custom exhaust” and had them cut the pre cat and replace with a piece of SS pipe for $106.25 (included tax). They f’d up the threads on the 02 bung so they replaced that for “free” (and sensor come to find out). They also threw in a new set of flange hardware and gasket.
Final thoughts on stock header, pre-cat delete, resonator delete, and JCW SS mufflers. Meh.
Maybe since I haven’t driven it in 3 months I really can’t say if it’s better. For $100, I’m def happy I went that route.
FWIW: There was way more pop and burble with the one-ball mod so I miss that.
Precat delete due to split weld
Necro-quote here, but did you go to Lou's? I've had mixed experiences with them, sometimes good sometimes bad, seems to depend on the specific location you go to. Luck of the draw there.
Hi everyone- new owner here. I have an exhaust leak that is throwing a CEL. My local Indy shop tried to weld it, but I don’t think they were able to weld all away around the pipe, so he recommended I go to a muffler shop to get it completely welded. Does anyone have a recommendation for a muffler shop near San Francisco?
Hi everyone- new owner here. I have an exhaust leak that is throwing a CEL. My local Indy shop tried to weld it, but I don’t think they were able to weld all away around the pipe, so he recommended I go to a muffler shop to get it completely welded. Does anyone have a recommendation for a muffler shop near San Francisco?
thanks!
I received a recommendation for Golden Muffler. I hope they can reweld my exhaust and the CEL will go away. 👍🏽
