So, I have an '05 S with 66,000 miles and a Borla catback. But above the cat, in the down pipe portion, below the steel braided thing, there is this bulbous part of the exhaust. It has what looks like a heat shield built in that comes down around it. A couple weeks ago I thought my exhaust sounded different. So I took it to my good friend, Scott who owns Motoring Magic in Thousand Oaks. We put it up on the lift and took a look at it. He said he could see a small crack, about even where that heat shield (I think that's what it is) comes down around the balbous thing (don't know what that bulboud thing does). I couldn't see the crack. So yesterday I was coming home from the valley, up Topanga. The noise goes away after the car gets warmed up, so I kinda forgot about it. I decided to take the pass road home into Simi Valley. As soon as I got on the gas hard, it let go. It's really loud now like there is no exhaust. I haven't been able to get under to see what it looks like. I am going to take it to Champion Muffler in the morning and have him look at it.

But, I am wondering what my options are. Scott says they can be welded and fixed. I am hoping while it's still on the car, as I am a little broke right now. But, I am wondering, can that thing be eliminated all together, by putting a down pipe in it's place? I can't remember if there is an O2 senser or any other senser plugged into it. Does anyone know what that bulbous thing is for? Is there an aftermarket solution?
Thanks for any help,
Shawn

 

Sounds like you are referring to the pre-cat... I don't see why eliminating the pre-cat would cause any issues, but given your money situation I'd go with the cheapest option... either just weld the crack or just replace the pre-cat with a pipe like you suggested.

GotMINI

 

That's funny because mine cracked just behind the cat last week. The shop welded her back together and it is OK for now, but a replacement is in the works. A new exhaust header is $1000 bucks.

 

it's $1300 plus install. But, I have been doing research. I think it's covered under the Federal and California emmisions warranty for 8 years/80,000 miles.

 

check this out! everyone should know about this. I'll let you know what happens after I see the dealer, oh I hate dealers.

https://www.northamericanmotoring.co...-warranty.html

 

For $1,300 why get a stock header when you could get a RMW header for same price lol.

 

https://www.northamericanmotoring.co...?product=14531

 

Or better yet, let Mini pay for it under the California and federal emissions warranty law!

 

Approaching 76K on an 05, but so far, it's not having any issues (no leaks, no CEL, no loud noise emitting from that area) and running a Milltek exhaust, but will the dealer still do any repairs or replacement or don't bother taking it in?

 

I have an 05 S with 81500 miles and something up near the pre cat and flex joint just cracked open today. This is the first failure I have had of any kind and I drive my car aggressively everyday.
What are my options????

 

Anyone????

 

Have it welded - aftermarket exhaust manifolds are not legal in CA.

 

How's your relationship with your MINI dealer? Maybe call MINI USA first, jot down names and times and direct phone line if you can get it.

I would not mention your track racing and NASCAR driving tho', tell you them your grandma drives faster than you.

G/L, keep us posted.

 

After seeing the damage welding was not an option, it would have cracked again for sure. Installed an OBX header with the stock main cat. No codes and passes smog easily plus I picked up a bit of power. All for $210 plus some time

 

Details!! and maybe a pic of your welded cat on the OBX header. This sounds like the best of both worlds.. extra performance plus smog legal without throwing codes. What's she sound like vs the stock setup?

 

The search function on this forum works well. This has been done before, many times it seems. A high flow cat has been mentioned as well but after seeing the stock main cat I feel a high flow will provide no gains as the stocker is very good. The pre cat is not. Its a spiral wound pile.