A 3 bolt flange or a ball and socket should be used between the header and downpipe. That would prevent a lot of leaks. Do the flex pipes ever break or is it just the welds?

 

Gee thats weird, i have pictures just like that. weld the flex back on the flange on the inside good to go, the problem is their only pressed on shitty like.

 

The problem is that you cannot reliably weld that type of flex like that. Our old ones you could. http://www.zzperformance.com/miscftp/IMG_6840.jpg

We were welding the flexes to the flange and this meant that only the red portion was welded to the flange. Failures could then occur when the ring broke off of the flex. Now we weld them to pipe so that the blue and red portions get welded and then weld the pipe to the flange.

 

didnt i state in my post that not every thing was perfect even when you do proper research and developemnt. read again. ty. i said there wouldnt be so many problems.....

to zoomer. im not taking anything out of context. you lied to customers about what was breaking your downpipes. you said it was caused by more power being added and mounts needing to be used for less stress to the exhaust joints\but regardless those people did have mounts and the d/p combo still broke. thats not out of context. thats a straight lie. i will post this once more. you lied to people. /end

 

Are you stupid man!!! I am clearly stating the fact that ZZP has some very serious issues when it comes to there "RESEARCH AND DEVELOPMENT DEPARTMENT" because just look at the posts on this thread and others, there are FAR more complaints about the problems with this mid length dp combo and various other products that come from ZZP. You have the ***** to knock HAHN???? For real dude, think about what you are saying for a minute. Before I purchased the Hahn stage V turbo conversion w/Hahn catback I done 6 months of research because thats what people who respect their hard earned money do before obligating to making such a significant transformation/purchase. I had not found "1" negative thing that anyone had said about Hahn rather than there product is tip top and they spends thousands of hours in their research and development. Bill Hahn Jr. can tell you himself and with his background with Cobalts and knowledge it is unsurpassed. Sure you think your smart by posting this ridiculous statement whereas you say "Since Hahn is so good at that, they couldn't have missed the part where the intake THEY made broke, sending a piece into a new LNF turbo completely ruining it". We are intelligent people here are we not? OFC things do happen from time to time, we are only human and when we do mods to our cars there is always the potential that something can go wrong but all the control we have is over our own RESEARCH. When I see threads like this it makes me soo nervous to ever make a purchase with ZZP. I hear that ZOOOMER is a great guy and I believe it. Hes probably a great guy with great intentions of running a smooth operation but he also must recognize that they have had SEVERE problems with some of there product..unlike companies like Hahn. You do your research kid and you come back to me with all the neg posts you can find about Hahn and then do the same for ZZP. I dont think Ill hear back from you because we both know the answer to what the findings will be. Also, Zooomer I do appologize for any negs I am saying about ZZP and I hope you can respect my opinion about you guys. I trust that ZZP is a great company and they will make corrections to their mistakes and who knows, Im always willing to try the company out someday but right now who could blame many of us for feeling a little uneasy at this point of time.

 

I did not lie. The downpipe construction was done the same way our Grand Prix units have been done for years. The Cobalts put a lot of additional stress on the parts compared to the GPs. That is why factory flexes break on cobalts. That is what I posted and the fact remains true to this day.

The mounts help the problem and we thought that this was the only issue. A lie would have been knowing the problem wasn't the mounts and saying it was. Further failure analysis showed that the fashion in which the parts were welded was reducing their strength. Not enough to have issues on GP, but enough to do so on LSJs. As soon as the issue was discovered, we posted the information (2 weeks after the post where I recommended mounts for cars with higher HP than stock). Parts were warranted either way.

If you look at the ZZP exhaust products, their welds, flanges, construction and compare to any other brands being sold here, it will be quite obvious our quality is superior. We had an issue with flex welding a year ago, it's been resolved.

 

man do you guys bitch alot

 

wow, i started an almost-epic thread!

 

 

Its not even the flex pipe that pisses me off its the other few hundred dollars ive had to spend trying to get it to stay together, not leak, or fit right.

The 3inch whisper exhaust does NOT fit the car. The resonator is too big and before you try to backpedal and blame the install I had it as high as it can go without resting on the body of the car and it still hit everything from speed bumps to random driveways. No the car was not lowered either, it was at stock height. Besides the resonator issue, the fitment is otherwise horrible and impossible to not clang on the rear suspension with lowering springs. It wont stay on the hangers either.

 

HOLY ****... lying and being mistaken are two totally different things.

Yes he did say that you need to add mounts, to keep the pipe from breaking, however 2 weeks later he came back and said "My guys found a flaw in the manufacturing process"

They acknowledged the problem, apologized, corrected it , and extended everyones warranty. They are paying for shipping, and gave credit to anyone that already had a problem. What more do you want?? Damn, if only every manufacturer in the world did this.

 

Dont you get it!!!!! Even after they "Corrected" the problem there was still numerous issues. Yes ZZP does govern themselves properly by offering to warrant there product but its still the fact of it being a pain in the friggin as* to still have down time with the car and have to be bothered to ship/receive the products right?? I may be mistaken here but I know for a fact that it would **** me right off especially seeing how many people are having problems.

 

IM pretty sure they arent going to credit me for the 400 dollars ive needed in repairs

 

No I don't understand. I have not heard of one person who has had a problem with the new design. I have searched, but I cannot find any pictures in the Gallery of a new broken downpipe, nor can I find any threads. If there are problems, they must be far and few between, and hidden.

Did you personally have a problem with your ZZP Header/ DP?

What I do understand is that yes its a pain in the ass to have your car down, but that could easily happen with OEM parts, or another aftermarket vendor.

I am not trying to **** anyone off. I understand that I am fighting an uphill battle here, and that I cannot change your mind. But realize that I have had good experiences with ZZP and I want to make sure that others hear that ZZP is a good company that will do what it takes to correct the issues, not sweep them under the rug.

Zooomer; Keep up what you guys are doing. I feel that your innovative spirit is helping the Cobalt community, and I feel you guys took the right steps to fix the problem.

 

probably not

 

[QUOTE=Zooomer;3734396]I did not lie. The downpipe construction was done the same way our Grand Prix units have been done for years. The Cobalts put a lot of additional stress on the parts compared to the GPs. That is why factory flexes break on cobalts. That is what I posted and the fact remains true to this day.

you designed cobalt downpipes based off a grand prix design? maybe you should try designing a cobalt header d/p for a cobalt

 

I agree. I think that ZZP is a great company with some flaws. Like I said several times already is in order for them to take there company to the next level they really need work in there R+D department. Once that is corrected then everything should be great. I do understand that things happen but in the mass quanity like this is unacceptable. Whomever engineered that DP combo should find a new line of work because that was an unexcusable mistake and too produce soo many w/o the knowledge of what has happened means only one thing....Not enough research and testing, ect.....

 

im tired of argueing i think we are all aware of zzp`s flaws. buy from them with caution, this is not the only bad product they have released on the market with massive problems.

 

Jordan.. This thread is Awesomeness.. Put it in your Sig :P

 

[QUOTE=Redefined1;3735511]you are an idiot, he said the same way, not the same one. Read things in context, or do you not know what that means?

 

I have to say that I purchased the midlength headers and downpipe(highflow cat, 3" to 2.5"). I believe three weeks after I performed the install the downpipe broke at the flex joint. I saw tha Zooomer posted a thread concerning the issue and that the warranty was extended. I could not afford to take my car down and send back the DP. I had a whole new flex welded on at Mervine's in Reading, PA (highly recommend them). Since Zooomer issued the warranty he was kind enough to give me credit for the amount of the exhaust repair with proof of purchase and a copy of the bill. Since that time I have not had any issues. No broken bolts, welds, etc. The only thing I could suggest to Zooomer would be to move the bung for the wideband so it can be installed more easily and not have to modify the heat shield.

 

lmao look at this joker. if he based it off a design for the grand prix that might be his mistake. oh wait tons of them broke. it was a gg. play again sometime

 

he said it was done the same way another cars was done for years... my wheels are held on by lugs which is the same way a geo metro's wheels are held on, oh sh*t I hope they still work tomorrow!

Oh man, I wanted mandrel bent exhaust but since it wasn't specifically made for my car originally i might have problems...

I could go on for days... I don't even own a ZZP product lol I'm just saying, sometimes this stuff happens, some people on here have had their DP for years and it didn't break with the original design, so even if they would have gotten a cobalt and left it there for a year without selling it to test it, it may not have broken.

To me it looks like these guys are doing everything in their power to get the old problem solved and help customers. I'm thinking of buying the combo because 1) its the cheapest and seems to be best bang for the buck and 2) if I have to get it all re-welded or welded at the connections it would still come up cheaper than buying some of those others.

 

That is the most ridiculous comment Ive seen on here in a while, are you seriously comparing lugs to a specially designed dp combo???? Are you mental? Thats like the dumbest thing I have heard... Vehicle specific product is what the dp combo was for and that is for the cobalt, not a gtp not a volvo. If what you are saying is correct then everything anyone makes should just be universal fit right? Or mabye they should have sent instructions saying "Here is your dp combo that wasnt tested under load and for that matter not even tested on a cobalt altogether but the gtp kinda looks the same so we copied that to make this everlasting dp". Go ahead and buy the ZZP dp combo and Im pretty sure you will get a good BANG for your buck. Not the way you expect it though

 

LMAO! nuff said