Quote:
Originally Posted by Jack
Two issues are at work, both can cause a fire. 1) Cracked cat weld which eventually fails and muffler separates from cat with clamp in place and 2) clamp failures at slip joint ...
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Just last weekend at the track I had failure #1 (described by Jack above) at the weld on the output side of the cat before the U-bend. It got noisy and exhaust gases were leaking from this crack that went almost all the way around the circumference of the pipe/flange, but luckily it never separated. My shop is going to try to reweld it. I suspect this is a temporary fix because this looks to me like a design flaw.
As a point of reference: this is a stock 2005 Elise; 23k miles; sees street, track, and autocross use.