Loud rattle from exhaust
Discussion
The occasional rattle from the exhuast has now got worse, and it is there almost all of the time. I think it is coming from the back of the box, just where the tail pipes exit. Sounds like a baffle has come loose. I have read of people having the baffles removed to prevent / cure this. Is this easy?
Also, anyone know of someone who can do this in North Herts area?
This rattle is embarassing now, so i need to get it fixed, and the MOT is looming.
Cheers
Pete
Also, anyone know of someone who can do this in North Herts area?
This rattle is embarassing now, so i need to get it fixed, and the MOT is looming.
Cheers
Pete
just got back from spin round the dales. panic
attack when loud rattle started from under car.had a grovel round underneath and it seems to be coming from inside silencer but no leaking. so i think i have the same problem with a loose baffle in my S3.
anybody any idea's how to fix or where to get just a
silencer until i save up for a stainless system.
attack when loud rattle started from under car.had a grovel round underneath and it seems to be coming from inside silencer but no leaking. so i think i have the same problem with a loose baffle in my S3.
anybody any idea's how to fix or where to get just a
silencer until i save up for a stainless system.
Hi Chris,
You and me both then mate
. I have checked under the car again today, and I think that the baffles in the square box are made from a zig-zag perferated plate welded along the length, as I can see angled witness weld marks on the sides of the box. My rattle is from the very back end, where the tail pipes exit, sounds like a bit is loose inside. I am planning on getting the boxed opened up / fixed /rewelded by a local bodyshop. I'll let you know how I get on.
You and me both then mate
. I have checked under the car again today, and I think that the baffles in the square box are made from a zig-zag perferated plate welded along the length, as I can see angled witness weld marks on the sides of the box. My rattle is from the very back end, where the tail pipes exit, sounds like a bit is loose inside. I am planning on getting the boxed opened up / fixed /rewelded by a local bodyshop. I'll let you know how I get on. 
Hi pete
Got the exhaust off tonight.Then ground off the welds
securing the top lid.Inside you find loads of glass
wadding then under that there is like you described a
zig zag mesh welded inside box, all appeared to be ok so far.But when you stand the system on its end there
was a loose piece of metal 100m/m x 75m/m sliding around under the mesh.So cut through the mesh retrieved the loose bit and hopefully tomorrow get my local welder to make as good. I was surprised how good the condition of system is considering its original.
Good luck Chris
Got the exhaust off tonight.Then ground off the welds
securing the top lid.Inside you find loads of glass
wadding then under that there is like you described a
zig zag mesh welded inside box, all appeared to be ok so far.But when you stand the system on its end there
was a loose piece of metal 100m/m x 75m/m sliding around under the mesh.So cut through the mesh retrieved the loose bit and hopefully tomorrow get my local welder to make as good. I was surprised how good the condition of system is considering its original.
Good luck Chris
I was going to cut the bottom out of the box to get access to the baffles, and then weld up again all with the pipe still on the car. But would it be better to take the complete pipe off and go in from the top ?
Also did you take to complete top off, or just locally close to where you could hear the rattle ?
And since you cut through the mesh, did you weld it up again internally or just leave a hole in it ?
Lots of questions, as I don't want to #@*& up the job.
Also did you take to complete top off, or just locally close to where you could hear the rattle ?
And since you cut through the mesh, did you weld it up again internally or just leave a hole in it ?
Lots of questions, as I don't want to #@*& up the job.
Hi pete
I thought it best to take top lid off the box because its already welded round top rim the bottom edge is folded and would be harder to cut.So just grind off the original weld down 2 long sides and 1 end. Insert a sharp chisel and tap it along and it just peels back, still held at the other end.
I had to slit the mesh and bend it back just enough to remove the loose bit then retack the mesh together (fiddly)
Its all been worth it, now all I can hear is the V6
roar and no distracting RATTLEEEEEEEEEEE
Chris
I thought it best to take top lid off the box because its already welded round top rim the bottom edge is folded and would be harder to cut.So just grind off the original weld down 2 long sides and 1 end. Insert a sharp chisel and tap it along and it just peels back, still held at the other end.
I had to slit the mesh and bend it back just enough to remove the loose bit then retack the mesh together (fiddly)
Its all been worth it, now all I can hear is the V6
roar and no distracting RATTLEEEEEEEEEEE
Chris
Hi Chris,
I was happily driving home yesterday when the car started to sound a bit like a loud tractor
I had another check under the car when I got home, and found a large hole, big enough to get my finger in, in the top seam of the front part of the oval section box, about 6" back from where the pipes enter 
So the car is laid up until the weekend when I will take the pipe off and see if I can get the hole patched and the rattle sorted. I guess I need a new system really, but i want to be running for the TVR meeting this sunday.
Why does this always happen when in the good weather?
Cheers
Pete
I was happily driving home yesterday when the car started to sound a bit like a loud tractor
I had another check under the car when I got home, and found a large hole, big enough to get my finger in, in the top seam of the front part of the oval section box, about 6" back from where the pipes enter So the car is laid up until the weekend
when I will take the pipe off and see if I can get the hole patched and the rattle sorted. I guess I need a new system really, but i want to be running for the TVR meeting this sunday. Why does this always happen when in the good weather?
Cheers
Pete
Hi Peter,
It would appear there can be all sorts of reasons for the 'tractor like rattling' from the exhaust!
I had the same problem which drove me mad.
Firstly I had the centre box cut open, baffles removed and the reverse cones re-welded. Sounded better but rattle returned as did my S3 to the garage. When the car was on the ramps a good bash about revealed the rattle to be coming from where the front pipes entered the silencer (centre). Removed the front pipes and found that the 'inner sleeves' of the front pipes were coming loose from the outer casing. This was a bit dissapointing as the front section is an ACT S/Steel part fitted about two years ago! Anyway the garaged removed the inner sections of the exhaust and Bingo! No more rattle.
The car now sounds awesome. Really deep, smooth and loud!
Something to consider.
Allthe best and good luck.
Pookie.
It would appear there can be all sorts of reasons for the 'tractor like rattling' from the exhaust!
I had the same problem which drove me mad.
Firstly I had the centre box cut open, baffles removed and the reverse cones re-welded. Sounded better but rattle returned as did my S3 to the garage. When the car was on the ramps a good bash about revealed the rattle to be coming from where the front pipes entered the silencer (centre). Removed the front pipes and found that the 'inner sleeves' of the front pipes were coming loose from the outer casing. This was a bit dissapointing as the front section is an ACT S/Steel part fitted about two years ago! Anyway the garaged removed the inner sections of the exhaust and Bingo! No more rattle.
The car now sounds awesome. Really deep, smooth and loud!
Something to consider.
Allthe best and good luck.
Pookie.
Hi All,
Will be getting the exhaust off this afternoon, and seeing what the damage is.
My local welder is going to reweld it all on Sunday morning, so I won't be able to make the Lunchtime Harpenden meeting as I will under the car reassembling it (hopefully)
All being well, will be back on the road on monday
Will be getting the exhaust off this afternoon, and seeing what the damage is.
My local welder is going to reweld it all on Sunday morning, so I won't be able to make the Lunchtime Harpenden meeting
as I will under the car reassembling it (hopefully) All being well, will be back on the road on monday
Hi Peter M.
I had exactly the same thing happen to me on my last S, and despite getting the hole very professionally welded up, the box split somewhere else nearby as CarZee was entering the circuit at Anglessey about 3 months later (a big hole that time !).. It sounded like a Nascar going round..
If the oval section is beginning to "go" I'd suggest getting a new exhaust perhaps..
Cheers,
Matt
I had exactly the same thing happen to me on my last S, and despite getting the hole very professionally welded up, the box split somewhere else nearby as CarZee was entering the circuit at Anglessey about 3 months later (a big hole that time !).. It sounded like a Nascar going round..
If the oval section is beginning to "go" I'd suggest getting a new exhaust perhaps.. Cheers,
Matt
I took the exhaust off the S2,it was broken in a big way. If you lifted it end to end it sounded like a bag of nails.
I cut open the top of the first box to get some of the debris out, and found that there was NO baffles or wadding remaining. Then I cut the lid off of the main box, and there was almost nothing there either . All the wadding had gone and only a small section of the grid was still there. Basically the pipe was straight through, except for piles of the debris in the way.
So I spoke to my welder, and he said that as it was good quality stainless steel, it would be worth repairing . So yesterday he:
1. Welded the front pipe entry points and reinforced with SS
2. Welded the rear pipe exit points and reinforced with SS
3. Cut out a thin part on the underside of the main box and inset a new piece of SS
4. Repaired the hole I cut in the top of the front box with SS
5. Made a new deflector plate inside the rear box
6. Welded in a new perforated baffle sheet in the rear box (only half length of the box as that is all we had)
7. Patched a hole in the side of the rear box with SS
8. Put the lid back on the back box, after I packed the baffles with glass fibre loft insulation
9. Rewelded the connections between the pipe and the down pipes.
The exhaust sounds a lot deeper now, but I have only ticked it over while the exhaust paste sets.
I cut open the top of the first box to get some of the debris out, and found that there was NO baffles or wadding remaining
. Then I cut the lid off of the main box, and there was almost nothing there either . All the wadding had gone and only a small section of the grid was still there. Basically the pipe was straight through, except for piles of the debris in the way. So I spoke to my welder, and he said that as it was good quality stainless steel, it would be worth repairing
. So yesterday he: 1. Welded the front pipe entry points and reinforced with SS
2. Welded the rear pipe exit points and reinforced with SS
3. Cut out a thin part on the underside of the main box and inset a new piece of SS
4. Repaired the hole I cut in the top of the front box with SS
5. Made a new deflector plate inside the rear box
6. Welded in a new perforated baffle sheet in the rear box (only half length of the box as that is all we had)
7. Patched a hole in the side of the rear box with SS
8. Put the lid back on the back box, after I packed the baffles with glass fibre loft insulation
9. Rewelded the connections between the pipe and the down pipes.
The exhaust sounds a lot deeper now, but I have only ticked it over while the exhaust paste sets.
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