Hey guys,

I purchased the mid-length header/ downpipe combo back in march. as soon as i installed it, i had the header-to-downpipe bolts break off. didn't take longer than a couple hours for that.

btw, the product was a mid-length header to 3" downpipe with magnaflow hi-flo cat to 2.5" bolt in exit. and i have an ingall's tq dampener set to the tightest setting. the engine does not hardly move at all

since then i have blown out a total of 9 header-to-downpipe gaskets. it's the 3" 2-bolt style. I have tried every which way to seal this thing, including 1 gasket (4 times), 2 gaskets (2 times) and 1 gasket with sealant (1 time). finally i gave up on the gasket and decided to live with the constant exhaust leak.

then last night, during a moderate (not hard) launch, the damn downpipe just broke. broke clean off - right at the flange, leading to the flexpipe. here's some pics :








i'm so pissed right now.... i'm back to stock exhaust until i can decide what to do

 

Damn that sucks man. My zzp exhaust work was top notch. Went in without a problem and never had anything go wrong. Maybe contact ZZP and see if they are willing to help you out. Downpipes obviously shouldn't just break.

 

talked to them about the gasket issue, haven't yet talked to them about the busted downpipe since it just happened yesterday

but how does a weld come completely off like that? just a shitty defect?

 

Sometimes **** just happens. Zooomer is a cool dude, I'm sure he'll help you out.

 

I feel you man, I have had the EXACT same problems, mine broke at exactly the same point

and i have a leak at the downpipe/resonator flange

 

i had my bolts came off but never broke the downpipe though

 

what did they do to fix your problems?

 

This has been said over and over again. ZZP IS HORRIBLE when it comes to there exhaust department. They have rattling resonators, bolts breaking, and flex pipes breaking. Hungry and I have had this discussion before. My downpipe broke at the flex pipe also, as did many many others. They do not WELD there flex pipes, they crimp them. The 2nd one I got was tach welded, but its absolutely ridiculous at the amounts of problems they have.

The bolt problem should have been solved by now, you probably got shipped an older set of bolts. Other than that, I really don't know what to say. Call them, and get another. That's what I did.

 

i'm actually thinking of going with a different header and downpipe now, looking specifically at vibrant or clear image. i don't think i want to stay with zzp, at least for the header, because how long will it be before this next one i get breaks too?

 

I didnt bother calling them, I didnt want the same thing happening again later so i just got the old one cut out and a new flex pipe WELDED in like its supposed to be. Still haved fixed the leak yet at the downpipe resonator area. I'm going to try some high temp RTV silicone gasket maker, it also has copper in it. So basically ill make my own gasket. I might tackle that on tuesday

 

you can see in the pics that are just 2 little welds inside for tacks proble to hold it untill they crimp it.if you want to save your downpipe find a welding shop and see if they can weld it back and then u should have no problem!! other then your gasket but i have used the stuff from napa it comes in like a cheesewiz like can great stuff or someting gaskit maker i used it on my 98 s10 and its great stuff(because the flang was bent from welding it (heat worp) to the pipe.) and keep in mind stainless is wek after any weld and can brake!!!! thats just my 2cents after being at a auto body/welding shop for 7yrs.

 

thanks for all your guys' responses. i will be calling them first thing tomorrow and getting this taken care of. i will have them replace this one, which, after i get it, will probably take it to an exhaust shop and get the whole thing done the right way

 

i did that twice already and still had it break in other places

 

same thing happened to me. join the crew

 

As of early this month ZZP has changed the Downpipe design. Now instead of the flex pipe being welded or crimped directley to the flange the flange is instead welded to 2 inches of pipe and then connected to the flex pipe. They also found a flaw in there welding process so they have also fixed that as well. Thus all older model downpipes have a 2 year warranty instead of one for this reason. They should warranty it with no problem and send you the new design.

 

Dude i had my pipe break at that exact same spot the second day i had it, i just took it to an exhaust shop and had it welded the right way for $20 bucks.

 

have it welded at a muffler shop.

 

I've head my mid combo on for about a month now and about a week ago it went raspy and I believe I have a pretty good leak. I'll get her in the air tomorrow.

 

I got the same thing and mine has blown the gaskets out 4 times. im actually on my 3rd flex pipe cuz those keep breaking to. i dont even drive the car hard either

 

anybody have this new one? how's it holding up?

 

I think the only ones that have the new welded flexpipes are stainless.

I'd take it to a weld shop and have them fix it up for you. It'd be cheaper than shipping it back to ZZP.

 

I've heard about this problem alot.Good thing I have a Vibrant.

 

another one ey? just fix what you have dont spend 600-800 for new stuff


but yeah.............. join the crew

 

https://www.cobaltss.net/forums/show...=121764&page=2

 

im i wrong to say that there is no good flex pipe for what we do to are cars. it is the weakest link in the chain but better then braking off a bolt in the head with the motor rock when you punch it to the floor and dump the clutch