I just finished installing a new Milltek exhaust on my '05 MCSa, with the help of my bro-in-law. The install is lots easier with a second person...

Anyway, it went in real easy, and everything fits nice except the tips are a bit too high -- one tip is touching the black valance on the bumper.

Does anyone have any ideas on lowering the tips a bit? I didn't really see any adjustability in the hangers.

Thanks!

BTW, I purchased the Milltek from Way @ Way Motor Works - great transaction, plenty of communication and delivery as promised. Thanks Way!

 

glad to hear that your Milltek experience was good. i bought one from another well-known source and have had a HORRIBLE experience. so i have yet to mount mine. i am giving them 1 more week to resolve my issues before i respond (legal action, mini forums) to them.

i am curious to hear how you can drop the tip clearance too.

good luck.

 

Hey BBD,

I had the same issue with the Milltek install. Some slight contact with the rear valence. I lived with it, now my tips have a nice custom fit, melting the rear valence a bit to the point where there is no contact now!

The in/out distance of the catback is adjustable--- have you tried messing with how much the tips protrude? That might change the angle of things and reduce contact. When the exhaust system heats up the tips expand outwards more, so you can get away with pushing the system in more when cold (and this might help mitigate the contact issue).

 

I'll let it go for a week or so and see if there's any melting. I may remove the valence and trim it back a bit.

Thanks!

 

Sorry to hear about your troubles - what happened?

Mine was short a couple washers but I found some laying around the house.

 

Sorry, I had no issue with the tips. I'm pretty sure that once u get it right, it'll be the last exhaust you'll ever want. The only reason I'm getting rid of mine is because I'm trading for an 06 JCW. If I don't like the JCW catback I'll get another Milltek; I liked it that much. Sounds like u don't have access to a torch as u could probably just heat it and beat it.

 

Ya gotta stack some washers to give it more stand-off, or it will melt the valence.
(BTW: I got my Milltek from Webb [very satisfied] & the tip about stacking washers from Way)

 

Are you suggesting to stack some washers underneath the hanger mounts, to let the hangers down a bit? I thought about that but didn't have a handy supply of washers. I wonder if I can get away with only doing that on the inside hangers, as they're much easier to get to than the outside ones.

 

That's what I did, just stacked some washers on the inside. Also trimmed the valence with a Demel for added insurance. I think I did more than I needed to. Haven't had any problems.

 

I used 4 or 5 (I don't exactly remember) 5/16th (I think) washers behind each of the 4 hangers. I don't recall it being difficult, but my MCS is an '03 with the old style hangers.

 

I'd use a nut or two. Trying to get washers to stay on the stud that hangs down while you force the exhaust up there is a giant PITA.

I too have had fitment issues with my Milltek.

 

Seems we all have. Mine was a hassle until I found a local custom shop to do some cutting and bending. I also waited a couple weeks for the right hangers to arrive, but in the meantime the local shop made a couple extensions. It's too bad about all the hassle because it is a nice system. Low back pressure and nice sound. My tips fell in just perfect. Interesting part is the expansion. When cold the tips are flush to the valance. When hot, they stick out 1/2 inch.

I'd take a wooden dowel, like a broom handle, two actually, and try gently bending the tips down. Make sure the dowels are all the way inside the tips.

btw, Chad told me every Milltek he's installed had to be fiddled with one way or another.

 

Just do the washer method. To make it easy, stack 4 or 5 washers together and place some tape around the edge to hold them while you install them. You can do it one hanger at a time as long as you make sure the other hanger on the same side is supporting it while you remove one hanger.

Do this and you'll love the Milltek. Great sound and performance.