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Exhaust flex pipe replacement

Robottrainer

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Everytime I crawl under this car and see that cheesy flex connector I say WTF! Not to mention the pipe is somewhat flattened. Has anyone undone this cheese on an oem system while retaining the cats? And on that topic, has anyone come up with a system that replaces the meltdown prone oem cats with better aftermarket ones that bolt up to the oem headers?
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engineermike

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Oh boy….

The stock gen3 flex joint isn’t so bad. It appears to retain the 2.50 diameter, unlike the slip connector. Want to see cheesy….look at the gen2. It’s round but it necks down to 2”.

On the cats, first of all the drivers side cat is built into the header so no aftermarket cat will easily bolt up. Secondly, the stock cats are ceramic substrate and thus, not very easy to melt. I believe the more common failure mode is thermal shock and fracturing. Aftermarket “high flow” cats are metal substrate and much easier to “melt” than ceramic.
 

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Go to a muffler shop?
 
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Robottrainer

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Oh boy….

The stock gen3 flex joint isn’t so bad. It appears to retain the 2.50 diameter, unlike the slip connector. Want to see cheesy….look at the gen2. It’s round but it necks down to 2”.

On the cats, first of all the drivers side cat is built into the header so no aftermarket cat will easily bolt up. Secondly, the stock cats are ceramic substrate and thus, not very easy to melt. I believe the more common failure mode is thermal shock and fracturing. Aftermarket “high flow” cats are metal substrate and much easier to “melt” than ceramic.
Anything flex is never a good idea. As for the cats, numerous guys with Roush stage 2 blowers are killing them with a few wide open blasts at the track.
 
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Robottrainer

Robottrainer

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Rapid Red

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They can fab such things ........ "a good one"
 
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Robottrainer

Robottrainer

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engineermike

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Anything flex is never a good idea.
Flex joints aren’t so bad. It’s how they deal with thermal expansion. The gt500 has one on each side.

As for the cats, numerous guys with Roush stage 2 blowers are killing them with a few wide open blasts at the track.
I didn’t say cats aren’t failing. Ive failed 3 myself. But none of them were melted is my point.
 

Rapid Red

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The Duesenberg had flex pipes.
 
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Robottrainer

Robottrainer

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The Duesenberg had flex pipes.
Back then you made do with what you had. T squares and machines driven with leather belts. Now with computer aided design, FMEA, simulators and computer aided manufacturing I would think they can do better. Except when accountants get involved.
 

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Anything flex is never a good idea. As for the cats, numerous guys with Roush stage 2 blowers are killing them with a few wide open blasts at the track.
The DEMON doesn't.. and it's the same manufacture type cat. Factory knows how to tune with cats intact. Most aftermarket tuners do not.
 
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Robottrainer

Robottrainer

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The DEMON doesn't.. and it's the same manufacture type cat. Factory knows how to tune with cats intact. Most aftermarket tuners do not.
Maybe Ford doesn't do a good job with their engine strategies. I know a few stock 2013 GT500s that burned up some cats. They appear the same as the ones that are on the 550. Roush works with Ford to do their tunes for the stage two set up. Several of those have burned up cats.
 

engineermike

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Dodge has pcm logic to slow the rate of heat-up of the cat. Ford doesn’t.

s550 gt500 cats looks the same externally as gt cats but the internals are way different.
 
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Robottrainer

Robottrainer

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Dodge has pcm logic to slow the rate of heat-up of the cat. Ford doesn’t.

s550 gt500 cats looks the same externally as gt cats but the internals are way different.
Are the gt500 cats better? I would assume they are. Are they a better alternative?
 

engineermike

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Are the gt500 cats better? I would assume they are. Are they a better alternative?
Yes I have a pair on my 2018 now. But they don’t fit super easily. And they have flex joints. :D

Mesh comparison, gt500 on right. Oh, and they are PRICEY.

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