I am attempting to install a Miltek catback system, and have run into a problem. I can't seem to allign the system and not have the exhaust tips touch the rear bumper. Before I start bending the mount ears, (and probably break them off), I thought I would ask my friends at NAM for their thoughts on the subject.

Thanks

 

You can shave material from the bumper molding so your tips clear it. Other people got longer rubber mounts. Hope that helps.

 

Put three stainless washers between each hanger bolt and the rubber hanger and clearance will not be an issue. It will take 24 washers in all, two sets of three for each hanger. My gap between the tips and the bumper cover is perfect and the exhaust gets a little MINI hard-on, grows in length, of about 1/2" when it is hot.



Cheers,

JBing

 

 

You can either put washers under the hangars, or just trim the flashing off the bumper trim like I did - to keep the tips tucked up tight.

 

Thanks for the help folks. I have done the trim, installed washers, and things are improving.......but not there yet. Today I will do a little hanger tweaking and hope for the best.

 

I just got longer hangers. Autozone P/No: 17219.

 

So, are all Miltek MCS exhausts improperly designed or is it just some exhausts or some MINI's?

 

I installed one on my car and two others on friends. Mine needed serious tweaking. The other cars fit without a hitch.

My MCS is an 03, the other two cars were an 02 and an 03. None of the cars had aero kits. My car, however, was the only one with an aftermarket header.

I did not bother to measure any of the exhaust hanger angles on either the cars nor the exhausts.

I would think that since no one is really reporting these problems with the stock exhaust, the discrepancies would be with the Milltek - no? Or maybe the smaller diameter of the stock tips allows for greater variance in the stock exhaust mounting position? Perhaps that 1/4" or so difference is made more noticeable by the installation of the larger tips.

 

Is there a different Milltek Sport exhaust setup for the newer 04/05 cars than for the older 02/03/early 04 cars? From what I understand, the late 04 cars, and all of the 05 cars, have a different exhaust hanger setup than do the earlier cars. The reason I'm asking is that I have an 05 MCS and I ordered a Milltex exhaust for it and so I'd like to know if I was sent the correct version of the exhaust system for my car. All the instructions that came with the exhaust say is that it's an 02 and on (but when I placed my order I specified that my car was a 2005).

Oh and BTW, my exhaust kit came with two separate metal exhaust hangers in the box that weren't attached to anything (and I don't see them in any of the photos of the kit as shown on the Webb Motorsport website). Where do those go?

Thanks!

 

When I put my Milltek on, I mistakenly installed [loosely] the intermediate pipe upside-down. Try rotating it 180 and refitting.

 

Those extra hangers mount on the inboard side of the mufflers, and you should have received (2) sets, one of which will work on your year of Mini.

 

Hi miniyellow,

Thanks for the information as it really helps!

When I first looked in the box, I only saw 1 set of the extra hangers (as the bag they should have been in was ripped apart and all four of the hangers were scattered all over the box). However, I just rechecked and there are indeed two sets (it would be nice if they told you that you only needed two of the four and which ones you will need for which year cars ).

BTW, my exhaust was packaged very poorly. The box was all split up and none of the parts were wrapped at all. In fact, I've just taken a look at the tips and one of them has a large dent in the side (I'm sure it was banged up during the shipping based on how tore up the box was). I can live with the dent though as it's not too bad and I think that I can bang it out.

I've seen photos of someone else's Milltek exhaust system and it was packaged up really nice with bubble wrap and all of the pieces being zipped tied together real nicely. Mine looks like it was just thrown into the box haphazardly with no concern for damage to the system.

I do have a question for you about the parts that should be in the box. My system included a packing list that mentioned that two gaskets should have been included. However, it is lined out with a black marker on the sheet and there aren't any gaskets in the box. Do you know if those gaskets are supposed to be there or not? I assume that they would be needed when bolting together the front silencer, link pipe, and or the rear silencer assembly (at the flanges). But, I guess the assembly paste they've included could be used instead.

It would be nice if Milltek included a pictorial representation of how the exhaust parts are to be assembled as I'm not sure if the front silencer bolts directly to the car's header, or if it bolts directly to the rear silencer assembly instead. For Milltek being such a great company, you'd think that they would have taken a bit more time to get the smaller details right. Oy!

Also, the packing slip mentions that 4 10MM washers should have been included, but none were with my system. However, the nuts being used look to me like they have the washers already built into them and so there is no need. Minor stuff I know, but still confusing all the same.

Thanks for your help.

 

Okay, I found a picture that shows that the front silencer bolts up directly to the header and then the link pipe goes between the front silencer and the rear silencer assembly. Cool!

Now, that still leaves the question of the gaskets being needed inbetween each of the flanges. I would assume that they would be needed as it doesn't make much sense to bolt them up metal to metal does it???

 

Sorry to hear about the bad packing and damaged part. That's the only problem I didn't have

I didn't receive and 10 mm washers, and not sure what they would be used for other than spacers to help align things. I also did not receive the Neccessary gaskets either, and still waiting for them to arrive. The included tube of muffler sealant cannot be used in place of the gasket however, and should only be used, (if at all), where the extension tube slides on. Also, if you install and find the tail pipes hitting the rear bumber, I highly recomend purchasing the Autozone muffler insulators suggested by Kenchan. I tried the washer spacers, trimmed the plastic bumper, and the problem wasn't resolved until I installed the Autozone hangers, part #17219. You will need four, and they are only $3.00 each.

If you will be installing via jackstands, by yourself, (like I did), don't assemble the whole system before mounting, (per instructions). It's a pain. Install the rear mufflers (slide into rubber hangers), then fasten the mount plate to the silencer and lift it up and set it on a cardboard box high enough to allow fastening to the existing catalitic converter. Next, slide on extender tube, then lift the forward section a few inches to meet the flange on rear muffler tube. I use a the box my jack stands came in, it was the perfect height.

Hope this helps.

 

Thanks for all of the great tips! I'll definitely give them all a try when installing my own exhaust. Although, I'm really tempted to complain and make them send me a new one due to the poor packaging, missing gaskets, and dented tip. BTW, if you didn't get the gaskets, what did you use in the mean time?

 

I'm not driving the car until gasket arrives. I will just loosen the flange and slide in gasket when, (if ever), it arrives.

I think returning your damaged system is your best move.