Multiple Exhaust fractures on a TDI (AFN)

[jed the spread]

I am just wondering if anyone else is getting broken exhaust bits every month or two?

I have one of those flex things on my exhaust but its along the J pipe and not right up net to the turbo. Its a stainless J pipe but the back box is the late, or bigger one. OK I do take it off road every now and again though I do take it easy really but I keep getting broken bits of the exhaust system



I have had the J pipe snap right next to the turbo,
Bottom turbo stud snap,
left hand bracket snap,
The moulded on bracket things on the back box (LHS) snap,
The bracket that holds the LHS exhaust mount onto the engine bar snap off.

All these things have happened at different times and I seem to be chasing things all over the place pushing the next breakage somewhere else along the exhaust system. Its not a big drama fixing stuff as I am teaching myself to weld and the practice is coming in handy but I was just wondering if this is coincidence or not. The engine runs super smooth and there isnt anything obvious why this stuff keeps happening.

Is it just me?

Jed

[jamesc76]

is it all stainless?? as it expands and contracts a lot more than mild steel, plus if your welding stainless with normal mig wire it wont help and that will crack!

[Oldiebut goodie]

That is the problem with stainless - it is far more brittle than normal mild steel exhausts and also the structure of the metal gets changed at every welded joint. It wouldn't take a lot of resonance of a thinner piece at a bracket/manifold for the cracks to start. Stainless has it's benefits and also drawbacks as you have found.

[jed the spread]

Thanks for your replies

The first bit that went was a stainless part and after the repair it has been sound, all the other parts are really thick mild steel. I guess its just ironing out any stress points that need beefing up a bit. Just wondered if anyone else with the same conversion had any of the same things?

jed

[ninja.turtle007]

After a flexi was fitted I haven't had any issues with the exhaust. None often is stainless.

[lloydy]

Stick a wbx in

[Cableguy]

Surprisingly, mine is holding up quite well. Although Baxters spotted a bust hanger.