OEM Exhaust rusted after four years. Recommendations?

[Cees Klumper]

Just maybe your exhaust is touching the car body which would cause lots of noise inside? Check underneath for the clearances.

[MadeinSweden1]

5 years ago I purchased a Starla exhaust system from FCP Euro to replace the original factory exhaust. Initially it was a nice replacement but after only 3.5 years the exhaust rusted right through to the point where the last two feet of the exhaust fell off one day while driving on the highway. I replaced the Starla with a Ferrita Sports exhaust and I couldn't be happier. In short, don't go the cheap way because you will only have to replace it again in the end. Especially if you have salty, long winters.
~Shane

[E Showell]

I have routinely purchased Borla/Starla mufflers and exhausts from FCP fully expecting them to last no longer than three years. Which, in my experience, proves about right in the Northeast for expected lifetime. I've done this for P80 vehicles where I can't justify doubling the "value" of the vehicle by adding an OEM exhaust at more than 2X the price for the aftermarket replacement. I have mailed at least one rusted out aftermarket exhaust to FCP for warrranty replacement (they were nice enough to let me hacksaw it down to size so it could fit in a box for shipment. My exhaust used to be among the pictures FCP had on its website touting their guaranty. There is some labor involved in replacing an exhaust every three years, but I think the trade off on spending considerably more on a better system is worth it.

[MadeinSweden1]

That sounds like a pretty good deal to me! I just couldn't resist the drop in price for the sports exhaust so I finally went for it. Vivaperformance has dropped the Ferrita to a very fair price. I bought the Starla originally for $175 bucks and that was a steal. I definitely got my money worth out of it.(Now the price has almost doubled for Starla on FCP) The Ferrita should sustain the tough winters and be a blast in the backroads in the spring, summer and fall. 265k put on, and many more to go, Swedish Pride!

[abscate]

Now the price has almost doubled for Starla on FCP)

We have to pay for all of Evans mufflers , now.

[scot850]

When I lived in Scotland, I would expect some muffler systems (like the Volvo 240) to sometimes last as little as 1-2 years before breaking. Strangely even OE mufflers never seem to last as long as the originals. Often manufacturers may resort to 'local' suppliers for stock in a country due to the size and weight of muffler systems, or change suppliers during the long life of our vehicles. Whatever the issue, I have never had an OE replacement last anywhere as long as the original.

Same comes with aftermarket 'stainless' steel muffler systems. Most I have found in North America that claim to be stainless are in fact T407 'stainless' which is just as bad for rusting as mild steel, maybe slightly less. If you want a muffler to last have a custom one made in T304 stainless and it will out live the car and probably you too!

Good Luck.

Neil.

[xHeart]

I do it on our cars every other year: viewtopic.php?f=10&t=87619