Pretty sure I worked out all the bugs. I had to rotate the bend pipe a small amount and it gave about 1/4" clearance with that cross piece. After 20 minute drive no rattle and sounds great.

opted for the tips rotated slightly to show the Milltek logo. I like how it contrasts the bumper.

 

good job!

it does sound great!

scott

 

Just an update. A week after fixing the low hanging pipe the rattle noise returned, but sounded like it was coming more forward towards the engine. Upon inspection the two nuts that attach the rubber spacers to the exhaust had come loose. These are located between the exhaust pipe and the upper shield. One nut was missing and the other was sitting on the exhaust flange (lucky). Shame on me for not tightening those enough I guess. When the exhaust is mounted space is very tight up there, but I was able to carefully bolt them back on and the noise disappears. 1 week and no issues.

The other issue I have been struggling with this a very loud drone in low gears and when going uphill. I also keep thinking there is a leak somewhere because when I drive by a wall I hear a "putt-putt-putt" sound which sounds like it's coming from under me. However when the car is fully stopped or in park revving the engine there is nothing. very strange. One thing I noticed is that the milltek pipe has large weld points where the clamp fits and the clamp rides up on these. The OEM exhaust does not have these. I unbolted the DP to exhaust clamp and applied silicon exhaust sealant to the joint. After the sealant cured it made a little difference, but not much. And I still cannot feel or see any leaks so I am not sure what to do now....dynomat the car?

 

Here's how the exhaust sounds:

http://www.youtube.com/watch?v=Zf70-...ature=youtu.be

 

on my car, the v-band clamp had a gasket between the dp and exhaust pipe ... the gasket makes the seal, not the v-band clamp itself ... link to photos of v-band clamp

http://www.ecstuning.com/Mini-2011-C...st/OE/ES40513/

no drone anywhere on my car ... it is louder under load (uphill or full throttle), but it is not exhaust drone

scott

 

Yeah I have the gasket in place. My concern is that the Akrapovic DP is not exactly in the same position as the stock DP. I found this out when installing it and had to move the flex connect exhaust pipe. The milltek made the situation slightly worse and had less flex. I did the best I could with brute strength to get the two pipes lined up.

And I guess it's not drone. At normal cruising speed there is no sound. But after 2K rpms accelerating or going up hill it's present. Although sometimes, like this morning, it is not even there which just has me guessing.

 

i have the stock DP, the fit was perfect

as to the sound or drone, i have none with the stock DP, i guess the high flow Akrapovic could make a difference

scott

 

yeah getting rid of the Akrapovic tomorrow. way too much of a headache. now i may have a dead o2 sensor to boot or not...we'll see once the stock is back on.

 

Your o2 sensor is probably fine. I had the same problem with an exhaust in my other car.

 

I will not say it's a complete victory but the loud noise above 2K rpms is gone after putting the stock back on. exhaust still sounds good. Time will tell on the CEL but after 15 mins of driving they did not return.

 

In case you are still wondering, I love my Milltek. I shopped around for a long time for the quietest performance exhaust I could find, and this one is definitely it, it is only a hair louder than stock.