New Bosal front pipe: smaller diameter???

[Nervous]

I am totally bummed. I've got a Maganflow front pipe, part no. 23892. And guess what? Its inner diameter at catalytic flange EVEN SMALLER THAN BOSAL's!!!! WTF?????
Pics:



Here is left - Magnaflow, center - Bosal, right - debris of original:



Here is the measurement of the flange pipe, it is still 6 cm:


Magnaflow - 5.7 cm! :


Original - still 6.5 cm:


WTF? How I suppose to install it? HELP!

[Nervous]

I've send email to Magnaflow's tech support with all of the photos above. The funniest thing is that they say on their website:

Each is designed to exact the original equipment specifications.

Doesn't seems to me like it.
Will see what they reply. But guys, what do you think about it? Am I the first who meets this kind of problem????

[Chris Crash]

Yikes. Did you tell bosal/rockauto about the problem too? I would.

[Nervous]

I told to rockauto, but no response yet. If I find bosal's tech support email then will send them too.
BTW, I am sorry I am using centimeters, but it is much easier to see a difference in sizes then in inches. However, looks to me both Magnaflow and Bosal were made for 2.25" center pipe however my car has 2.5" pipe...

[Chris Crash]

I would call them directly. The amount of money you spent with them, you need to make this right. I'm sure the bosal exhaust wasn't cheap either.

[Nervous]

sent email to bosal to... Bosal is $250, Magnaflow is $320. I want them to see photos I made. But if they don't reply by email, I'll call.

[Chris Crash]

With that kind of money invested I would definitely be pissed off, haha. Good thinking about the pictures!

[SilverSoarer]

Actually, I went through this exact same thing with Bosal (spent over an hour on the phone with their manager) and as well as Magnaflow.

This is why I mentioned to you the 1.5" ID for flex pipe section in your other posting/thread - ended up re-using the stock pipe and MIG welding in a new flex section instead. I recommend the same for the catalytic converter - weld in a new one to the existing piping.

As long as the total length is approximate and the ID is approximate - neither Bosal or Magnaflow (or any other aftermarket exhaust manufacturer) will do much to match the exact ID size of the original pipe.

The only other alternative is OEM and that is about $1100 - too much.

[Nervous]

Yeah, man, probably that would be faster, cheaper and easier.... I just hoped on "direct OE fit", it looked so easy to unbolt the old one and bolt in the new one!

So, you saying you had EXACTLY the same experience, huh? What was the result of those phone calls? What did they say?

[SilverSoarer]

Well Magnaflow customer service was not helpful at all (I had all the specs in terms of measurements) - basically they said they can't do anything.

Bosal's manufacturing manager recommended a refund for their pipe after we discussed the dimensions and length as well as warranty.

I also called Walker, Arvin-Mentor, Eastern Catalytic, and some custom exhaust shops (for a total stainless front pipe quote came to over $600). None of the aftermarket manufacturers could guarantee a precision fit - only an "OEM direct fit"

In the end, my only choice was to MIG weld a new flex section into existing pipe.

If Toyota's price was $400-500 instead of $1100+ - I would have gone with that.

[Nervous]

very interesting.... How do they stay in business then? In my understanding, "OEM direct fit" is DIRECT fit like OEM. Ok, there are two of us who had problems. But what about all other people who buy these products? How do they install them?????

[SilverSoarer]

Most people take it to a mechanic (very few people work on cars these days, even fewer do their own exhaust work since it's so messy).

Most mechanics will jerry rig and monkey wrench an exhaust to fit. Go to Midas, Mieneke, or Speedy - that's a huge part of their whole business - since customers rarely see the underneath of their car.

The DIYers who install these probably don't measure the port dimensions - most are just happy to have a new exhaust that will eliminate leaks and noises and pass emissions.

[Nervous]

Originally Posted by SilverSoarer

The DIYers who install these probably don't measure the port dimensions - most are just happy to have a new exhaust that will eliminate leaks and noises and pass emissions.

I would be happy not to measure if it fits!
I doubt nobody else here, on TN, installed a new front pipe from Bosal or Maganflow themselves.... That would be very weird, actually.....

[lemegacool]

i had a bosal installed in mine last year, then i say my car lacks power lol.... daaaammm i'soooo doing a CUSTOM exhaust starting with the y pipe...

[Gibson99]

one way to make it fit would be to cut off the protruding section of pipe from your existing mid-pipe to make it a flat flange.