exhaust pipe - manufacturer defect or car defect?

drkshdw · 03-26-2019, 10:38 AM

Had to replace the complete exhaust system on my DD because of rusted flanges (this past record winter was hell on the 20 year old Toyota). All was well for a few days with the new system and then an exhaust leak popped up. It progressively got worse over the week following.

Below is a pic of where the leak is. It's right along the seam of the resonator pipe. Wasn't like this when I put it on the car (at least I don't remember it like this and it didn't leak for a few days). So what does the collective Pelican trust think? Is this the result of bad manufacturing or was this caused by the car?

No CEL's. No stored codes. Runs fine. Needs a new thermostat (stuck open) but I wouldn't think that would have an effect on the exhaust. I mean, it's like there's a weld there but the seam is split open for a good foot downstream (right side of the pipe in the pic) like there was excessive pressure in the pipe causing it to split open (you can see light through it with a flashlight). Can that happen? I don't know what to think but if it was the cars fault, I'd like to know so I can look into fixing whatever the cause may be.

And for the record, I got it from Summit and when I called, they rushed a new pipe and return shipping label for the old one with no questions asked. Superb customer service that some online car retailers could learn from. I digress. Pic...

1990C4S · 03-26-2019, 10:43 AM

That is sccchitti material that needs to be replaced under warranty or welded properly.

pwd72s · 03-26-2019, 10:44 AM

Not a clue, but if it happens again, you'll know.

BTW, I also have had great service from Summit

wdfifteen · wdfifteen's Garage

What is downstream from the split? Another muffler or anything that might be clogged?

Also, check for banana in the tailpipe.

99% sure it's a bad weld on the pipe.

drkshdw · 03-26-2019, 11:11 AM

Quote:

Originally Posted by wdfifteen

What is downstream from the split? Another muffler or anything that might be clogged?

Also, check for banana in the tailpipe.

99% sure it's a bad weld on the pipe.

The split is after the resonator (on the same pipe) and before the muffler (separate). Muffler is new and makes the usual exhaust clouds in the morning so I assume it's not clogged or obstructed.

herr_oberst · 03-26-2019, 11:16 AM

Check out the picture Patrick posted on his bug thread of the brand new shocks.

Everything you can buy these days can be defective right out of the box...put the new one on, and see what happens. If it starts to leak again in the same place, my money would be on the car.....

Bob Kontak · Bob Kontak's Garage

Quote:

Originally Posted by wdfifteen

99% sure it's a bad weld on the pipe.

+1

So much for a quick visual inspection at the facility cranking these out.

vonsmog · 03-26-2019, 02:04 PM

Made in China I bet, just a bad weld on the pipe. So some 12 year old girl working the machine that makes the pipe screwed up. Damn Kids!!!!!

lendaddy · 04:38 PM

It's just a bad weld, it was like that when you put in on I assure you. I've been in the tube/pipe industry for over 20 years, that's a common flaw (that should have been caught in house).

*while this one was probably made by a 12 year old Chinese girl I can tell you that men in America with 20+ years experience in the industry still do this every week. It does generally get caught though. I've eaten six figures worth of scrap for such nonsense.

drkshdw · 03-26-2019, 04:57 PM

Quote:

Originally Posted by lendaddy

It's just a bad weld, it was like that when you put in on I assure you. I've been in the tube/pipe industry for over 20 years, that's a common flaw (that should have been caught in house).

*while this one was probably made by a 12 year old Chinese girl I can tell you that men in America with 20+ years experience in the industry still do this every week. It does generally get caught though. I've eaten six figures worth of scrap for such nonsense.

Sad this has become commonplace. I paid extra for the 'Made in the USA' sticker on the pipe but after using this companies exhaust for 3 cars now, I'm pretty sure a 12 year old Chinese girl could weld better with her eyes closed and her hands behind her back. But it's the price I have to pay since Toyota no longer makes these and it's either this 'American Made' crap or crappier Chinese crap. Part of the disposable car society we live in now I guess. I'm just glad it's crappy workmanship and not my car.

wdfifteen · wdfifteen's Garage

Quote:

Originally Posted by drkshdw

Sad this has become commonplace. I paid extra for the 'Made in the USA' sticker on the pipe but after using this companies exhaust for 3 cars now, I'm pretty sure a 12 year old Chinese girl could weld better with her eyes closed and her hands behind her back.

If a human had welded it, even a 12 year old, it would have cost a fortune. This is the work of a welding machine that wasn’t set up or maintained properly.