Stainless Works MS3 Downpipe - FAILURE
 

This is my Stainless Works downpipe, which has been on my car for about 18k miles. I purchased it used with <5k miles on it, so we're talking less than 23k miles in less than two years. The flange weld almost completely failed. Total, there was about 1.5" of weld material left holding the flange on. The flange was almost falling off of the bell (you could move it independently of the pipe). The pipe material next to the flange weld was starting to crack. Presumably, this is a result of the weld failure and the exhaust movement.

I have upgraded all engine mounts, which I am sure contributed to accelerated wear once the weld starting eroding. I had a friend at a local shop re-weld the flange for me. It is back on and hopefully better than new.


UPDATE 1/26/10:

Well shit, that isnt good.

wow...thats not fucking good

Wow, that sucks man. I'd contact stainless works and let them know about it, even if they can't fix it for you. If I sold a product and it failed early, but out of warranty, I'd still like to know about it in case there's an underlying problem with my manufacturing process.

Actually I think the opposite is true. If the engine is well anchored with firm engine mounts, less movement typically puts less stress on exhaust components. So it sounds like you really did all you could to help this part last.

The exact same thing happened to my sw catless dp. when i first got it the flange was warped all to hell and had to be welded and resurfaced just to have a hope of not leaking. next i took it off to stock out for a warranty job and it looked just like yours, cracked almost all the way around.

Ah, forgot to mention that - thanks. A few minutes before my original post, I sent SW an email just to notify them of the failure (since the warranty doesn't apply to me as a second owner). I attached all pictures seen here.

You could be right that the engine mounts reduced the stress, idk. The exhaust still has the ability to move a bit since it is all rubber mounts under the car.

from these pix it looks like my 4 yr old made it regardless of your mounts etc
jesus


sorry to hear bud

man...that sucks.
how did you discover it was in the condition its in? did you hear the exhaust leaking?

I felt like I was going to die from exhaust fumes every time I drove my car, haha. When the car was cold, i put my hand near the flange and had a friend start it. Exhaust pulses everywhere was the indicator.

Wow...that sucks man...I almost went with their TBE thankfully I dod not buy it...Sorry bro

Wow. That is too bad. Let us know what SW says/does.

sounds like a cast bellmouth is done on the better downpipes for a reason hmmmmm

Hey man-

Stainless Works took care of me when i had an issue and were awesome about it. Give anthony there a call or email him.

His email is anthony@stainlessworks.net he might be able to help you out directly.

Haha, I doubt that. I've seen numerous high power cars with 304/321 headers, which get much hotter, perform just fine. It was definitely a junk weld, in this case.

MATTNUCCI, thanks for the tip, but I don't think they will do anything for me. I have already had the dp rewelded. I haven't received an email back from them, and I'm not sure that I will. I'll give it a couple more days, and then I may give them a call.

Give me a ring - We made a design change not to long ago that will fix your issue.

Thanks
-Anthony
800-878-3635

NJSPEED3 ^^^ approves this brownie vendor's message

I talked to Anthony a bit ago. SW has changed their methods of constructing the MS3 downpipes, so current downpipes will not have this problem. The newer downpipes are welded on both the inside and outside, to create a better/stronger weld. They offered to repair mine at no cost. Anyone else who has the 'old style' can do this, as well. Since I already had mine re-welded, I am not going to have it repaired by SW.

Good customer service, nonetheless. SW has a reputation for building high quality exhaust pieces, and I wouldn't be afraid of buying one of the updated exhausts for the MS3.